Control system arrangements for a modular surgical instrument

ABSTRACT

A surgical instrument comprising a handle and an elongate shaft is disclosed. In various instances, the battery pack comprises a power source couplable to the motor and a display. The elongate shaft comprises a processor and a memory couplable to the processor. In various instances, the memory comprises a control program which, when executed, causes the processor to initiate a desired function. In various instances, the end effector comprises a sensing circuit configured to detect a condition of the end effector. The sensing circuit is in signal communication with the processor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This non-provisional application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 62/578,793,entitled SURGICAL INSTRUMENT WITH REMOTE RELEASE, filed Oct. 30, 2017,of U.S. Provisional Patent Application Ser. No. 62/578,804, entitledSURGICAL INSTRUMENT HAVING DUAL ROTATABLE MEMBERS TO EFFECT DIFFERENTTYPES OF END EFFECTOR MOVEMENT, filed Oct. 30, 2017, of U.S. ProvisionalPatent Application Ser. No. 62/578,817, entitled SURGICAL INSTRUMENTWITH ROTARY DRIVE SELECTIVELY ACTUATING MULTIPLE END EFFECTOR FUNCTIONS,filed Oct. 30, 2017, of U.S. Provisional Patent Application Ser. No.62/578,835, entitled SURGICAL INSTRUMENT WITH ROTARY DRIVE SELECTIVELYACTUATING MULTIPLE END EFFECTOR FUNCTIONS, filed Oct. 30, 2017, of U.S.Provisional Patent Application Ser. No. 62/578,844, entitled SURGICALINSTRUMENT WITH MODULAR POWER SOURCES, filed Oct. 30, 2017, and of U.S.Provisional Patent Application Ser. No. 62/578,855, entitled SURGICALINSTRUMENT WITH SENSOR AND/OR CONTROL SYSTEMS, filed Oct. 30, 2017, thedisclosures of which are incorporated by reference herein in theirentirety. This non-provisional application claims the benefit under 35U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No.62/665,129, entitled SURGICAL SUTURING SYSTEMS, filed May 1, 2018, ofU.S. Provisional Patent Application Ser. No. 62/665,139, entitledSURGICAL INSTRUMENTS COMPRISING CONTROL SYSTEMS, filed May 1, 2018, ofU.S. Provisional Patent Application Ser. No. 62/665,177, entitledSURGICAL INSTRUMENTS COMPRISING HANDLE ARRANGEMENTS, filed May 1, 2018,of U.S. Provisional Patent Application Ser. No. 62/665,128, entitledMODULAR SURGICAL INSTRUMENTS, filed May 1, 2018, of U.S. ProvisionalPatent Application Ser. No. 62/665,192, entitled SURGICAL DISSECTORS,filed May 1, 2018, and of U.S. Provisional Patent Application Ser. No.62/665,134, entitled SURGICAL CLIP APPLIER, filed May 1, 2018, thedisclosures of which are incorporated by reference herein in theirentirety.

BACKGROUND

The present disclosure relates to surgical systems and, in variousarrangements, to grasping instruments that are designed to grasp thetissue of a patient, dissecting instruments configured to manipulate thetissue of a patient, clip appliers configured to clip the tissue of apatient, and suturing instruments configured to suture the tissue of apatient, among others.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 illustrates a surgical system comprising a handle and severalshaft assemblies—each of which are selectively attachable to the handlein accordance with at least one embodiment;

FIG. 2 is an elevational view of the handle and one of the shaftassemblies of the surgical system of FIG. 1;

FIG. 3 is a partial cross-sectional perspective view of the shaftassembly of FIG. 2;

FIG. 4 is another partial cross-sectional perspective view of the shaftassembly of FIG. 2;

FIG. 5 is a partial exploded view of the shaft assembly of FIG. 2;

FIG. 6 is a partial cross-sectional elevational view of the shaftassembly of FIG. 2;

FIG. 7 is an elevational view of a drive module of the handle of FIG. 1;

FIG. 8 is a cross-sectional perspective view of the drive module of FIG.7;

FIG. 9 is an end view of the drive module of FIG. 7;

FIG. 10 is a partial cross-sectional view of the interconnection betweenthe handle and shaft assembly of FIG. 2 in a locked configuration;

FIG. 11 is a partial cross-sectional view of the interconnection betweenthe handle and shaft assembly of FIG. 2 in an unlocked configuration;

FIG. 12 is a cross-sectional perspective view of a motor and a speedreduction gear assembly of the drive module of FIG. 7;

FIG. 13 is an end view of the speed reduction gear assembly of FIG. 12;

FIG. 14 is a partial perspective view of an end effector of the shaftassembly of FIG. 2 in an open configuration;

FIG. 15 is a partial perspective view of the end effector of FIG. 14 ina closed configuration;

FIG. 16 is a partial perspective view of the end effector of FIG. 14articulated in a first direction;

FIG. 17 is a partial perspective view of the end effector of FIG. 14articulated in a second direction;

FIG. 18 is a partial perspective view of the end effector of FIG. 14rotated in a first direction;

FIG. 19 is a partial perspective view of the end effector of FIG. 14rotated in a second direction;

FIG. 20 is a partial cross-sectional perspective view of the endeffector of FIG. 14 detached from the shaft assembly of FIG. 2;

FIG. 21 is an exploded view of the end effector of FIG. 14 illustratedwith some components removed;

FIG. 22 is an exploded view of a distal attachment portion of the shaftassembly of FIG. 2;

FIG. 22A is an exploded view of the distal portion of the shaft assemblyof FIG. 2 illustrated with some components removed;

FIG. 23 is another partial cross-sectional perspective view of the endeffector of FIG. 14 detached from the shaft assembly of FIG. 2;

FIG. 24 is a partial cross-sectional perspective view of the endeffector of FIG. 14 attached to the shaft assembly of FIG. 2;

FIG. 25 is a partial cross-sectional perspective view of the endeffector of FIG. 14 attached to the shaft assembly of FIG. 2;

FIG. 26 is another partial cross-sectional perspective view of the endeffector of FIG. 14 attached to the shaft assembly of FIG. 2;

FIG. 27 is a partial cross-sectional view of the end effector of FIG. 14attached to the shaft assembly of FIG. 2 depicting a first, second, andthird clutch of the end effector;

FIG. 28 depicts the first clutch of FIG. 27 in an unactuated condition;

FIG. 29 depicts the first clutch of FIG. 27 in an actuated condition;

FIG. 30 depicts the second clutch of FIG. 27 in an unactuated condition;

FIG. 31 depicts the second clutch of FIG. 27 in an actuated condition;

FIG. 32 depicts the third clutch of FIG. 27 in an unactuated condition;

FIG. 33 depicts the third clutch of FIG. 27 in an actuated condition;

FIG. 34 depicts the second and third clutches of FIG. 27 in theirunactuated conditions and the end effector of FIG. 14 locked to theshaft assembly of FIG. 2;

FIG. 35 depicts the second clutch of FIG. 27 in its unactuated conditionand the third clutch of FIG. 27 in its actuated condition;

FIG. 36 depicts the second and third clutches of FIG. 27 in theiractuated conditions and the end effector of FIG. 14 unlocked from theshaft assembly of FIG. 2;

FIG. 37 is a partial cross-sectional view of a shaft assembly inaccordance with at least one alternative embodiment comprising sensorsconfigured to detect the conditions of the first, second, and thirdclutches of FIG. 27;

FIG. 38 is a partial cross-sectional view of a shaft assembly inaccordance with at least one alternative embodiment comprising sensorsconfigured to detect the conditions of the first, second, and thirdclutches of FIG. 27;

FIG. 39 depicts the first and second clutches of FIG. 38 in theirunactuated conditions and a sensor in accordance with at least onealternative embodiment;

FIG. 40 depicts the second and third clutches of FIG. 38 in theirunactuated conditions and a sensor in accordance with at least onealternative embodiment;

FIG. 41 is a partial cross-sectional view of a shaft assembly inaccordance with at least one embodiment;

FIG. 42 is a partial cross-sectional view of the shaft assembly of FIG.41 comprising a clutch illustrated in an unactuated condition;

FIG. 43 is a partial cross-sectional view of the shaft assembly of FIG.41 illustrating the clutch in an actuated condition;

FIG. 44 is a partial cross-sectional view of a shaft assembly inaccordance with at least one embodiment comprising first and secondclutches illustrated in an unactuated condition;

FIG. 45 is a perspective view of the handle drive module of FIG. 7 andone of the shaft assemblies of the surgical system of FIG. 1;

FIG. 46 is another perspective view of the handle drive module of FIG. 7and the shaft assembly of FIG. 45;

FIG. 47 is a partial cross-sectional view of the shaft assembly of FIG.45 attached to the handle of FIG. 1;

FIG. 48 is another partial cross-sectional view of the shaft assembly ofFIG. 45 attached to the handle of FIG. 1;

FIG. 49 is a partial cross-sectional perspective view of the shaftassembly of FIG. 45;

FIG. 50 is a schematic of the control system of the surgical system ofFIG. 1.

FIG. 51 is an elevational view of the handle and one of the shaftassemblies of the surgical system of FIG. 1;

FIG. 52 is a perspective view of the handle of FIG. 1 and the shaftassembly of FIG. 2;

FIG. 53 is a partial top plan view of the handle of FIG. 1 and the shaftassembly of FIG. 2;

FIG. 54 is a partial elevational view of the handle of FIG. 1 and theshaft assembly of FIG. 2;

FIG. 55 is a perspective view of the drive module of FIG. 7 and a powermodule of FIG. 1;

FIG. 56 is a perspective view of the drive module of FIG. 7 and thepower module of FIG. 55;

FIG. 57 is an elevational view of the drive module of FIG. 7 and thepower module of FIG. 55 attached to a side battery port of the drivemodule;

FIG. 58 is a partial cross-sectional view of the connection between theside battery port of the drive module of FIG. 7 and the power module ofFIG. 55;

FIG. 59 is an elevational view of the handle drive module of FIG. 7, thepower module of FIG. 45 attached to a proximal battery port of thehandle drive module, and the shaft assembly of FIG. 45 attached to thedrive module;

FIG. 60 is a top view of the drive module of FIG. 7 and the power moduleof FIG. 45 attached to the proximal battery port;

FIG. 61 is an elevational view of the drive module of FIG. 7 and thepower module of FIG. 45 attached to the proximal battery port;

FIG. 62 is a perspective view of the drive module of FIG. 7 and thepower module of FIG. 45 attached to the proximal battery port;

FIG. 63 is a perspective view of the power module of FIG. 45 detachedfrom the drive module of FIG. 7;

FIG. 64 is another perspective view of the power module of FIG. 45detached from the drive module of FIG. 7;

FIG. 65 is an elevational view of the power module of FIG. 45 attachedto the proximal battery port of the drive module of FIG. 7;

FIG. 66 is a partial cross-sectional view of the connection betweenproximal battery port of the drive module of FIG. 7 and the power moduleof FIG. 45;

FIG. 67 is an elevational view of the power module of FIG. 55 attachedto the proximal battery port of the drive module of FIG. 7;

FIG. 68 is a partial cross-sectional view of the connection between theproximal battery port of the drive module of FIG. 7 and the power moduleof FIG. 55;

FIG. 69 is an elevational view of an attempt to connect the power moduleof FIG. 45 to the side battery port of the drive module of FIG. 7;

FIG. 70 is a cross-sectional detail view of an attempt to connect thepower module of FIG. 45 to the side battery port of the drive module ofFIG. 7;

FIG. 71 is a perspective view of the power module of FIG. 45 attached tothe proximal battery port of the drive module of FIG. 7 and the powermodule of FIG. 55 attached to the side battery port;

FIG. 72 is a cross-sectional view of the power module of FIG. 45attached to the proximal battery port of the drive module of FIG. 7 andthe power module of FIG. 55 attached to the side battery port;

FIG. 73 is a perspective view of a portion of a surgical instrumentcomprising selectively attachable modular components in accordance withat least one aspect of the present disclosure;

FIG. 74 illustrates an electrical architecture of the surgicalinstrument of FIG. 73 in accordance with at least one aspect of thepresent disclosure;

FIG. 75 is a partial cross-sectional perspective view of a handle of thesurgical instrument of FIG. 73 in accordance with at least one aspect ofthe present disclosure;

FIG. 76 is a perspective view of a system of magnetic elements arrangedon the handle and a shaft of the surgical instrument of FIG. 73 inaccordance with at least one aspect of the present disclosure;

FIG. 77 is a perspective view of a system of magnetic elements arrangedon the handle and the shaft of the surgical instrument of FIG. 73 inaccordance with at least one aspect of the present disclosure;

FIG. 78 is a perspective view of the system of magnetic elements of FIG.77 aligning the shaft with the handle of the surgical instrument inaccordance with at least one aspect of the present disclosure;

FIG. 79 is a perspective view of a flex circuit for use in the surgicalinstrument of FIG. 73 in accordance with at least one aspect of thepresent disclosure;

FIG. 79A is a detail perspective view of a primary strain relief portionof the flex circuit of FIG. 79 in accordance with at least one aspect ofthe present disclosure;

FIG. 79B is a detail perspective view of a secondary strain reliefportion of the flex circuit of FIG. 79 in accordance with at least oneaspect of the present disclosure;

FIG. 79C is a detail perspective view of control circuit componentsincorporated into a flexible plastic of the flex circuit of FIG. 79 inaccordance with at least one aspect of the present disclosure;

FIG. 80 is a perspective view of a flex circuit for use in combinationwith the flex circuit of FIG. 79 in accordance with at least one aspectof the present disclosure;

FIG. 81A is a perspective view of the flex circuit of FIG. 79 prior tobeing electrically coupled with the flex circuit of FIG. 80 inaccordance with at least one aspect of the present disclosure;

FIG. 81B is a perspective view of the flex circuit of FIG. 79electrically coupled to the flex circuit of FIG. 80 in accordance withat least one aspect of the present disclosure;

FIG. 82 is a perspective view of a surgical suturing instrumentcomprising a handle, a shaft, and an end effector;

FIG. 83 is a logic flow diagram of a process depicting a control programfor controlling a surgical instrument;

FIG. 84 is a perspective view of surgical suturing instrument handlecomprising a motor;

FIG. 85 is a partial cross-sectional view of the surgical suturinginstrument handle of FIG. 82; and

FIG. 86 is an exploded view of a suturing cartridge for use with asurgical suturing system.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. patentapplications that were filed on even date herewith and which are eachherein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. ______, entitled SURGICAL SUTURINGINSTRUMENT CONFIGURED TO MANIPULATE TISSUE USING MECHANICAL ANDELECTRICAL POWER; Attorney Docket No. END8567USNP1/180100-1;

U.S. patent application Ser. No. ______, entitled SURGICAL SUTURINGINSTRUMENT COMPRISING A CAPTURE WIDTH WHICH IS LARGER THAN TROCARDIAMETER; Attorney Docket No. END8567USNP2/180100-2;

U.S. patent application Ser. No. ______, entitled SURGICAL SUTURINGINSTRUMENT COMPRISING A NON-CIRCULAR NEEDLE; Attorney Docket No.END8567USNP3/180100-3;

U.S. patent application Ser. No. ______, entitled ELECTRICAL POWEROUTPUT CONTROL BASED ON MECHANICAL FORCES; Attorney Docket No.END8567USNP4/180100-4;

U.S. patent application Ser. No. ______, entitled REACTIVE ALGORITHM FORSURGICAL SYSTEM; Attorney Docket No. END8567USNP5/180100-5;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTCOMPRISING AN ADAPTIVE ELECTRICAL SYSTEM; Attorney Docket No.END8568USNP1/180101-1;

U.S. patent application Ser. No. ______, entitled ADAPTIVE CONTROLPROGRAMS FOR A SURGICAL SYSTEM COMPRISING MORE THAN ONE TYPE OFCARTRIDGE; Attorney Docket No. END8568USNP3/180101-3;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTSYSTEMS COMPRISING BATTERY ARRANGEMENTS; Attorney Docket No.END8569USNP1/180102-1;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTSYSTEMS COMPRISING HANDLE ARRANGEMENTS; Attorney Docket No.END8569USNP2/180102-2;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTSYSTEMS COMPRISING FEEDBACK MECHANISMS; Attorney Docket No.END8569USNP3/180102-3;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTSYSTEMS COMPRISING LOCKOUT MECHANISMS; Attorney Docket No.END8569USNP4/180102-4;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTSCOMPRISING A LOCKABLE END EFFECTOR SOCKET; Attorney Docket No.END8570USNP1/180103-1;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTSCOMPRISING A SHIFTING MECHANISM; Attorney Docket No.END8570USNP2/180103-2;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTSCOMPRISING A SYSTEM FOR ARTICULATION AND ROTATION COMPENSATION; AttorneyDocket No. END8570USNP3/180103-3;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTSCOMPRISING A BIASED SHIFTING MECHANISM; Attorney Docket No.END8570USNP4/180103-4;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTSCOMPRISING AN ARTICULATION DRIVE THAT PROVIDES FOR HIGH ARTICULATIONANGLES; Attorney Docket No. END8570USNP5/180103-5;

U.S. patent application Ser. No. ______, entitled SURGICAL DISSECTORSAND MANUFACTURING TECHNIQUES; Attorney Docket No. END8571USNP1/180104-1;

U.S. patent application Ser. No. ______, entitled SURGICAL DISSECTORSCONFIGURED TO APPLY MECHANICAL AND ELECTRICAL ENERGY; Attorney DocketNo. END8571USNP2/180104-2;

U.S. patent application Ser. No. ______, entitled SURGICAL CLIP APPLIERCONFIGURED TO STORE CLIPS IN A STORED STATE; Attorney Docket No.END8572USNP1/180105-1;

U.S. patent application Ser. No. ______, entitled SURGICAL CLIP APPLIERCOMPRISING AN EMPTY CLIP CARTRIDGE LOCKOUT; Attorney Docket No.END8572USNP2/180105-2;

U.S. patent application Ser. No. ______, entitled SURGICAL CLIP APPLIERCOMPRISING AN AUTOMATIC CLIP FEEDING SYSTEM; Attorney Docket No.END8572USNP3/180105-3;

U.S. patent application Ser. No. ______, entitled SURGICAL CLIP APPLIERCOMPRISING ADAPTIVE FIRING CONTROL; Attorney Docket No.END8572USNP4/180105-4; and

U.S. patent application Ser. No. ______, entitled SURGICAL CLIP APPLIERCOMPRISING ADAPTIVE CONTROL IN RESPONSE TO A STRAIN GAUGE CIRCUIT;Attorney Docket No. END8572USNP5/180105-5.

Applicant of the present application owns the following U.S. patentapplications that were filed on May 1, 2018 and which are each hereinincorporated by reference in their respective entireties:

U.S. Patent Application Ser. No. 62/665,129, entitled SURGICAL SUTURINGSYSTEMS;

U.S. Provisional Patent Application Ser. No. 62/665,139, entitledSURGICAL INSTRUMENTS COMPRISING CONTROL SYSTEMS;

U.S. Patent Application Ser. No. 62/665,177, entitled SURGICALINSTRUMENTS COMPRISING HANDLE ARRANGEMENTS;

U.S. Patent Application Ser. No. 62/665,128, entitled MODULAR SURGICALINSTRUMENTS;

U.S. Patent Application Ser. No. 62/665,192, entitled SURGICALDISSECTORS; and

U.S. Patent Application Ser. No. 62/665,134, entitled SURGICAL CLIPAPPLIER.

Applicant of the present application owns the following U.S. patentapplications that were filed on Feb. 28, 2018 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/908,021, entitled SURGICALINSTRUMENT WITH REMOTE RELEASE;

U.S. patent application Ser. No. 15/908,012, entitled SURGICALINSTRUMENT HAVING DUAL ROTATABLE MEMBERS TO EFFECT DIFFERENT TYPES OFEND EFFECTOR MOVEMENT;

U.S. patent application Ser. No. 15/908,040, entitled SURGICALINSTRUMENT WITH ROTARY DRIVE SELECTIVELY ACTUATING MULTIPLE END EFFECTORFUNCTIONS;

U.S. patent application Ser. No. 15/908,057, entitled SURGICALINSTRUMENT WITH ROTARY DRIVE SELECTIVELY ACTUATING MULTIPLE END EFFECTORFUNCTIONS;

U.S. patent application Ser. No. 15/908,058, entitled SURGICALINSTRUMENT WITH MODULAR POWER SOURCES; and

U.S. patent application Ser. No. 15/908,143, entitled SURGICALINSTRUMENT WITH SENSOR AND/OR CONTROL SYSTEMS.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Oct. 30, 2017 and which are each hereinincorporated by reference in their respective entireties:

U.S. Provisional Patent Application Ser. No. 62/578,793, entitledSURGICAL INSTRUMENT WITH REMOTE RELEASE;

U.S. Provisional Patent Application Ser. No. 62/578,804, entitledSURGICAL INSTRUMENT HAVING DUAL ROTATABLE MEMBERS TO EFFECT DIFFERENTTYPES OF END EFFECTOR MOVEMENT;

U.S. Provisional Patent Application Ser. No. 62/578,817, entitledSURGICAL INSTRUMENT WITH ROTARY DRIVE SELECTIVELY ACTUATING MULTIPLE ENDEFFECTOR FUNCTIONS;

U.S. Provisional Patent Application Ser. No. 62/578,835, entitledSURGICAL INSTRUMENT WITH ROTARY DRIVE SELECTIVELY ACTUATING MULTIPLE ENDEFFECTOR FUNCTIONS;

U.S. Provisional Patent Application Ser. No. 62/578,844, entitledSURGICAL INSTRUMENT WITH MODULAR POWER SOURCES; and

U.S. Provisional Patent Application Ser. No. 62/578,855, entitledSURGICAL INSTRUMENT WITH SENSOR AND/OR CONTROL SYSTEMS.

Applicant of the present application owns the following U.S. ProvisionalPatent Applications, filed on Dec. 28, 2017, the disclosure of each ofwhich is herein incorporated by reference in its entirety:

U.S. Provisional Patent Application Ser. No. 62/611,341, entitledINTERACTIVE SURGICAL PLATFORM;

U.S. Provisional Patent Application Ser. No. 62/611,340, entitledCLOUD-BASED MEDICAL ANALYTICS; and

U.S. Provisional Patent Application Ser. No. 62/611,339, entitled ROBOTASSISTED SURGICAL PLATFORM.

Applicant of the present application owns the following U.S. ProvisionalPatent Applications, filed on Mar. 28, 2018, each of which is hereinincorporated by reference in its entirety:

U.S. Provisional Patent Application Ser. No. 62/649,302, entitledINTERACTIVE SURGICAL SYSTEMS WITH ENCRYPTED COMMUNICATION CAPABILITIES;

U.S. Provisional Patent Application Ser. No. 62/649,294, entitled DATASTRIPPING METHOD TO INTERROGATE PATIENT RECORDS AND CREATE ANONYMIZEDRECORD;

U.S. Provisional Patent Application Ser. No. 62/649,300, entitledSURGICAL HUB SITUATIONAL AWARENESS;

U.S. Provisional Patent Application Ser. No. 62/649,309, entitledSURGICAL HUB SPATIAL AWARENESS TO DETERMINE DEVICES IN OPERATINGTHEATER;

U.S. Provisional Patent Application Ser. No. 62/649,310, entitledCOMPUTER IMPLEMENTED INTERACTIVE SURGICAL SYSTEMS;

U.S. Provisional Patent Application Ser. No. 62/649,291, entitled USE OFLASER LIGHT AND RED-GREEN-BLUE COLORATION TO DETERMINE PROPERTIES OFBACK SCATTERED LIGHT;

U.S. Provisional Patent Application Ser. No. 62/649,296, entitledADAPTIVE CONTROL PROGRAM UPDATES FOR SURGICAL DEVICES;

U.S. Provisional Patent Application Ser. No. 62/649,333, entitledCLOUD-BASED MEDICAL ANALYTICS FOR CUSTOMIZATION AND RECOMMENDATIONS TO AUSER;

U.S. Provisional Patent Application Ser. No. 62/649,327, entitledCLOUD-BASED MEDICAL ANALYTICS FOR SECURITY AND AUTHENTICATION TRENDS ANDREACTIVE MEASURES;

U.S. Provisional Patent Application Ser. No. 62/649,315, entitled DATAHANDLING AND PRIORITIZATION IN A CLOUD ANALYTICS NETWORK;

U.S. Provisional Patent Application Ser. No. 62/649,313, entitled CLOUDINTERFACE FOR COUPLED SURGICAL DEVICES;

U.S. Provisional Patent Application Ser. No. 62/649,320, entitled DRIVEARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS;

U.S. Provisional Patent Application Ser. No. 62/649,307, entitledAUTOMATIC TOOL ADJUSTMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS; and

U.S. Provisional Patent Application Ser. No. 62/649,323, entitledSENSING ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS.

Applicant of the present application owns the following U.S. patentapplications, filed on Mar. 29, 2018, each of which is hereinincorporated by reference in its entirety:

U.S. patent application Ser. No. 15/940,641, entitled INTERACTIVESURGICAL SYSTEMS WITH ENCRYPTED COMMUNICATION CAPABILITIES;

U.S. patent application Ser. No. 15/940,648, entitled INTERACTIVESURGICAL SYSTEMS WITH CONDITION HANDLING OF DEVICES AND DATACAPABILITIES;

U.S. patent application Ser. No. 15/940,656, entitled SURGICAL HUBCOORDINATION OF CONTROL AND COMMUNICATION OF OPERATING ROOM DEVICES;

U.S. patent application Ser. No. 15/940,666, entitled SPATIAL AWARENESSOF SURGICAL HUBS IN OPERATING ROOMS;

U.S. patent application Ser. No. 15/940,670, entitled COOPERATIVEUTILIZATION OF DATA DERIVED FROM SECONDARY SOURCES BY INTELLIGENTSURGICAL HUBS;

U.S. patent application Ser. No. 15/940,677, entitled SURGICAL HUBCONTROL ARRANGEMENTS;

U.S. patent application Ser. No. 15/940,632, entitled DATA STRIPPINGMETHOD TO INTERROGATE PATIENT RECORDS AND CREATE ANONYMIZED RECORD;

U.S. patent application Ser. No. 15/940,640, entitled COMMUNICATION HUBAND STORAGE DEVICE FOR STORING PARAMETERS AND STATUS OF A SURGICALDEVICE TO BE SHARED WITH CLOUD BASED ANALYTICS SYSTEMS;

U.S. patent application Ser. No. 15/940,645, entitled SELF DESCRIBINGDATA PACKETS GENERATED AT AN ISSUING INSTRUMENT;

U.S. patent application Ser. No. 15/940,649, entitled DATA PAIRING TOINTERCONNECT A DEVICE MEASURED PARAMETER WITH AN OUTCOME;

U.S. patent application Ser. No. 15/940,654, entitled SURGICAL HUBSITUATIONAL AWARENESS;

U.S. patent application Ser. No. 15/940,663, entitled SURGICAL SYSTEMDISTRIBUTED PROCESSING;

U.S. patent application Ser. No. 15/940,668, entitled AGGREGATION ANDREPORTING OF SURGICAL HUB DATA;

U.S. patent application Ser. No. 15/940,671, entitled SURGICAL HUBSPATIAL AWARENESS TO DETERMINE DEVICES IN OPERATING THEATER;

U.S. patent application Ser. No. 15/940,686, entitled DISPLAY OFALIGNMENT OF STAPLE CARTRIDGE TO PRIOR LINEAR STAPLE LINE;

U.S. patent application Ser. No. 15/940,700, entitled STERILE FIELDINTERACTIVE CONTROL DISPLAYS;

U.S. patent application Ser. No. 15/940,629, entitled COMPUTERIMPLEMENTED INTERACTIVE SURGICAL SYSTEMS;

U.S. patent application Ser. No. 15/940,704, entitled USE OF LASER LIGHTAND RED-GREEN-BLUE COLORATION TO DETERMINE PROPERTIES OF BACK SCATTEREDLIGHT;

U.S. patent application Ser. No. 15/940,722, entitled CHARACTERIZATIONOF TISSUE IRREGULARITIES THROUGH THE USE OF MONO-CHROMATIC LIGHTREFRACTIVITY; and

U.S. patent application Ser. No. 15/940,742, entitled DUAL CMOS ARRAYIMAGING.

Applicant of the present application owns the following U.S. patentapplications, filed on Mar. 29, 2018, each of which is hereinincorporated by reference in its entirety:

U.S. patent application Ser. No. 15/940,636, entitled ADAPTIVE CONTROLPROGRAM UPDATES FOR SURGICAL DEVICES;

U.S. patent application Ser. No. 15/940,653, entitled ADAPTIVE CONTROLPROGRAM UPDATES FOR SURGICAL HUBS;

U.S. patent application Ser. No. 15/940,660, entitled CLOUD-BASEDMEDICAL ANALYTICS FOR CUSTOMIZATION AND RECOMMENDATIONS TO A USER;

U.S. patent application Ser. No. 15/940,679, entitled CLOUD-BASEDMEDICAL ANALYTICS FOR LINKING OF LOCAL USAGE TRENDS WITH THE RESOURCEACQUISITION BEHAVIORS OF LARGER DATA SET;

U.S. patent application Ser. No. 15/940,694, entitled CLOUD-BASEDMEDICAL ANALYTICS FOR MEDICAL FACILITY SEGMENTED INDIVIDUALIZATION OFINSTRUMENT FUNCTION;

U.S. patent application Ser. No. 15/940,634, entitled CLOUD-BASEDMEDICAL ANALYTICS FOR SECURITY AND AUTHENTICATION TRENDS AND REACTIVEMEASURES;

U.S. patent application Ser. No. 15/940,706, entitled DATA HANDLING ANDPRIORITIZATION IN A CLOUD ANALYTICS NETWORK; and

U.S. patent application Ser. No. 15/940,675, entitled CLOUD INTERFACEFOR COUPLED SURGICAL DEVICES.

Applicant of the present application owns the following U.S. patentapplications, filed on Mar. 29, 2018, each of which is hereinincorporated by reference in its entirety:

U.S. patent application Ser. No. 15/940,627, entitled DRIVE ARRANGEMENTSFOR ROBOT-ASSISTED SURGICAL PLATFORMS;

U.S. patent application Ser. No. 15/940,637, entitled COMMUNICATIONARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS;

U.S. patent application Ser. No. 15/940,642, entitled CONTROLS FORROBOT-ASSISTED SURGICAL PLATFORMS;

U.S. patent application Ser. No. 15/940,676, entitled AUTOMATIC TOOLADJUSTMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS;

U.S. patent application Ser. No. 15/940,680, entitled CONTROLLERS FORROBOT-ASSISTED SURGICAL PLATFORMS;

U.S. patent application Ser. No. 15/940,683, entitled COOPERATIVESURGICAL ACTIONS FOR ROBOT-ASSISTED SURGICAL PLATFORMS;

U.S. patent application Ser. No. 15/940,690, entitled DISPLAYARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS; and

U.S. patent application Ser. No. 15/940,711, entitled SENSINGARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS.

Applicant of the present application owns the following U.S. ProvisionalPatent Applications, filed on Mar. 30, 2018, each of which is hereinincorporated by reference in its entirety:

U.S. Provisional Patent Application Ser. No. 62/650,887, entitledSURGICAL SYSTEMS WITH OPTIMIZED SENSING CAPABILITIES;

U.S. Provisional Patent Application Ser. No. 62/650,877, entitledSURGICAL SMOKE EVACUATION SENSING AND CONTROLS;

U.S. Provisional Patent Application Ser. No. 62/650,882, entitled SMOKEEVACUATION MODULE FOR INTERACTIVE SURGICAL PLATFORM; and

U.S. Provisional Patent Application Ser. No. 62/650,898, entitledCAPACITIVE COUPLED RETURN PATH PAD WITH SEPARABLE ARRAY ELEMENTS.

Applicant of the present application owns the following U.S. ProvisionalPatent Application, filed on Apr. 19, 2018, which is herein incorporatedby reference in its entirety:

U.S. Provisional Patent Application Ser. No. 62/659,900, entitled METHODOF HUB COMMUNICATION.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”), and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes”, or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes”, or “contains” one or more features possesses thoseone or more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical instrument, such as a grasper, for example, can comprise ahandle, a shaft extending from the handle, and an end effector extendingfrom the shaft. In various instances, the end effector comprises a firstjaw and a second jaw, wherein one or both of the jaws are movablerelative to the other to grasp the tissue of a patient. That said, anend effector of a surgical instrument can comprise any suitablearrangement and can perform any suitable function. For instance, an endeffector can comprise first and second jaws configured to dissect orseparate the tissue of a patient. Also, for instance, an end effectorcan be configured to suture and/or clip the tissue of a patient. Invarious instances, the end effector and/or shaft of the surgicalinstrument are configured to be inserted into a patient through atrocar, or cannula, and can have any suitable diameter, such asapproximately 5 mm, 8 mm, and/or 12 mm, for example. U.S. patentapplication Ser. No. 11/013,924, entitled TROCAR SEAL ASSEMBLY, now U.S.Pat. No. 7,371,227, is incorporated by reference in its entirety. Theshaft can define a longitudinal axis and at least a portion of the endeffector can be rotatable about the longitudinal axis. Moreover, thesurgical instrument can further comprise an articulation joint which canpermit at least a portion of the end effector to be articulated relativeto the shaft. In use, a clinician can rotate and/or articulate the endeffector in order to maneuver the end effector within the patient.

A surgical instrument system is depicted in FIG. 1. The surgicalinstrument system comprises a handle assembly 1000 which is selectivelyusable with a shaft assembly 2000, a shaft assembly 3000, a shaftassembly 4000, a shaft assembly 5000, and/or any other suitable shaftassembly. The shaft assembly 2000 is attached to the handle assembly1000 in FIG. 2 and the shaft assembly 4000 is attached to the handleassembly 1000 in FIG. 45. The shaft assembly 2000 comprises a proximalportion 2100, an elongate shaft 2200 extending from the proximal portion2100, a distal attachment portion 2400, and an articulation joint 2300rotatably connecting the distal attachment portion 2400 to the elongateshaft 2200. The shaft assembly 2000 further comprises a replaceable endeffector assembly 7000 attached to the distal attachment portion 2400.The replaceable end effector assembly 7000 comprises a jaw assembly 7100configured to be opened and closed to clamp and/or manipulate the tissueof a patient. In use, the end effector assembly 7000 can be articulatedabout the articulation joint 2300 and/or rotated relative to the distalattachment portion 2400 about a longitudinal axis to better position thejaw assembly 7100 within the patient, as described in greater detailfurther below.

Referring again to FIG. 1, the handle assembly 1000 comprises, amongother things, a drive module 1100. As described in greater detail below,the drive module 1100 comprises a distal mounting interface whichpermits a clinician to selectively attach one of the shaft assemblies2000, 3000, 4000, and 5000, for example, to the drive module 1100. Thus,each of the shaft assemblies 2000, 3000, 4000, and 5000 comprises anidentical, or an at least similar, proximal mounting interface which isconfigured to engage the distal mounting interface of the drive module1100. As also described in greater detail below, the mounting interfaceof the drive module 1100 mechanically secures and electrically couplesthe selected shaft assembly to the drive module 1100. The drive module1100 further comprises at least one electric motor, one or more controlsand/or displays, and a controller configured to operate the electricmotor—the rotational output of which is transmitted to a drive system ofthe shaft assembly attached to the drive module 1100. Moreover, thedrive module 1100 is usable with one ore more power modules, such aspower modules 1200 and 1300, for example, which are operably attachableto the drive module 1100 to supply power thereto.

Further to the above, referring again to FIGS. 1 and 2, the handle drivemodule 1100 comprises a housing 1110, a first module connector 1120, anda second module connector 1120′. The power module 1200 comprises ahousing 1210, a connector 1220, one or more release latches 1250, andone or more batteries 1230. The connector 1220 is configured to beengaged with the first module connector 1120 of the drive module 1100 inorder to attach the power module 1200 to the drive module 1100. Theconnector 1220 comprises one or more latches 1240 which mechanicallycouple and fixedly secure the housing 1210 of the power module 1200 tothe housing 1110 of the drive module 1100. The latches 1240 are movableinto disengaged positions when the release latches 1250 are depressed sothat the power module 1200 can be detached from the drive module 1100.The connector 1220 also comprises one or more electrical contacts whichplace the batteries 1230, and/or an electrical circuit including thebatteries 1230, in electrical communication with an electrical circuitin the drive module 1100.

Further to the above, referring again to FIGS. 1 and 2, the power module1300 comprises a housing 1310, a connector 1320, one or more releaselatches 1350, and one or more batteries 1330 (FIG. 47). The connector1320 is configured to be engaged with the second module connector 1120′of the drive module 1100 to attach the power module 1300 to the drivemodule 1100. The connector 1320 comprises one or more latches 1340 whichmechanically couple and fixedly secure the housing 1310 of the powermodule 1300 to the housing 1110 of the drive module 1100. The latches1340 are movable into disengaged positions when the release latches 1350are depressed so that the power module 1300 can be detached from thedrive module 1100. The connector 1320 also comprises one or moreelectrical contacts which place the batteries 1330 of the power module1300, and/or an electrical power circuit including the batteries 1330,in electrical communication with an electrical power circuit in thedrive module 1100.

Further to the above, the power module 1200, when attached to the drivemodule 1100, comprises a pistol grip which can allow a clinician to holdthe handle 1000 in a manner which places the drive module 1100 on top ofthe clinician's hand. The power module 1300, when attached to the drivemodule 1100, comprises an end grip which allows a clinician to hold thehandle 1000 like a wand. The power module 1200 is longer than the powermodule 1300, although the power modules 1200 and 1300 can comprise anysuitable length. The power module 1200 has more battery cells than thepower module 1300 and can suitably accommodate these additional batterycells owing to its length. In various instances, the power module 1200can provide more power to the drive module 1100 than the power module1300 while, in some instances, the power module 1200 can provide powerfor a longer period of time. In some instances, the housing 1110 of thedrive module 1100 comprises keys, and/or any other suitable features,which prevent the power module 1200 from being connected to the secondmodule connector 1120′ and, similarly, prevent the power module 1300from being connected to the first module connector 1120. Such anarrangement can assure that the longer power module 1200 is used in thepistol grip arrangement and that the shorter power module 1300 is usedin the wand grip arrangement. In alternative embodiments, the powermodule 1200 and the power module 1300 can be selectively coupled to thedrive module 1100 at either the first module connector 1120 or thesecond module connector 1120′. Such embodiments provide a clinician withmore options to customize the handle 1000 in a manner suitable to them.

In various instances, further to the above, only one of the powermodules 1200 and 1300 is coupled to the drive module 1100 at a time. Incertain instances, the power module 1200 can be in the way when theshaft assembly 4000, for example, is attached to the drive module 1100.Alternatively, both of the power modules 1200 and 1300 can be operablycoupled to the drive module 1100 at the same time. In such instances,the drive module 1100 can have access to power provided by both of thepower modules 1200 and 1300. Moreover, a clinician can switch between apistol grip and a wand grip when both of the power modules 1200 and 1300are attached to the drive module 1100. Moreover, such an arrangementallows the power module 1300 to act as a counterbalance to a shaftassembly, such as shaft assemblies 2000, 3000, 4000, or 5000, forexample, attached to the drive module 1100.

Referring to FIGS. 7 and 8, the handle drive module 1100 furthercomprises a frame 1500, a motor assembly 1600, a drive system 1700operably engaged with the motor assembly 1600, and a control system1800. The frame 1500 comprises an elongate shaft that extends throughthe motor assembly 1600. The elongate shaft comprises a distal end 1510and electrical contacts, or sockets, 1520 defined in the distal end1510. The electrical contacts 1520 are in electrical communication withthe control system 1800 of the drive module 1100 via one or moreelectrical circuits and are configured to convey signals and/or powerbetween the control system 1800 and the shaft assembly, such as theshaft assembly 2000, 3000, 4000, or 5000, for example, attached to thedrive module 1100. The control system 1800 comprises a printed circuitboard (PCB) 1810, at least one microprocessor 1820, and at least onememory device 1830. The board 1810 can be rigid and/or flexible and cancomprise any suitable number of layers. The microprocessor 1820 and thememory device 1830 are part of a control circuit defined on the board1810 which controls the operation of the motor assembly 1600, asdescribed in greater detail below.

Referring to FIGS. 12 and 13, the motor assembly 1600 comprises anelectric motor 1610 including a housing 1620, a drive shaft 1630, and agear reduction system. The electric motor 1610 further comprises astator including windings 1640 and a rotor including magnetic elements1650. The stator windings 1640 are supported in the housing 1620 and therotor magnetic elements 1650 are mounted to the drive shaft 1630. Whenthe stator windings 1640 are energized with an electric currentcontrolled by the control system 1800, the drive shaft 1630 is rotatedabout a longitudinal axis. The drive shaft 1630 is operably engaged witha first planetary gear system 1660 which includes a central sun gear andseveral planetary gears operably intermeshed with the sun gear. The sungear of the first planetary gear system 1660 is fixedly mounted to thedrive shaft 1630 such that it rotates with the drive shaft 1630. Theplanetary gears of the first planetary gear system 1660 are rotatablymounted to the sun gear of a second planetary gear system 1670 and,also, intermeshed with a geared or splined inner surface 1625 of themotor housing 1620. As a result of the above, the rotation of the firstsun gear rotates the first planetary gears which rotate the second sungear. Similar to the above, the second planetary gear system 1670further comprises planetary gears 1665 (FIG. 13) which drive a thirdplanetary gear system and, ultimately, the drive shaft 1710. Theplanetary gear systems 1660, 1670, and 1680 co-operate to gear down thespeed applied to the drive shaft 1710 by the motor shaft 1620. Variousalternative embodiments are envisioned without a speed reduction system.Such embodiments are suitable when it is desirable to drive the endeffector functions quickly. Notably, the drive shaft 1630 comprises anaperture, or hollow core, extending therethrough through which wiresand/or electrical circuits can extend.

The control system 1800 is in communication with the motor assembly 1600and the electrical power circuit of the drive module 1100. The controlsystem 1800 is configured to control the power delivered to the motorassembly 1600 from the electrical power circuit. The electrical powercircuit is configured to supply a constant, or at least nearly constant,direct current (DC) voltage. In at least one instance, the electricalpower circuit supplies 3 VDC to the control system 1800. The controlsystem 1800 comprises a pulse width modulation (PWM) circuit which isconfigured to deliver voltage pulses to the motor assembly 1600. Theduration or width of the voltage pulses, and/or the duration or widthbetween the voltage pulses, supplied by the PWM circuit can becontrolled in order to control the power applied to the motor assembly1600. By controlling the power applied to the motor assembly 1600, thePWM circuit can control the speed of the output shaft of the motorassembly 1600. In addition to or in lieu of a PWM circuit, the controlsystem 1800 can include a frequency modulation (FM) circuit. Asdiscussed in greater detail below, the control system 1800 is operablein more than one operating mode and, depending on the operating modebeing used, the control system 1800 can operate the motor assembly 1600at a speed, or a range of speeds, which is determined to be appropriatefor that operating mode.

Further to the above, referring again to FIGS. 7 and 8, the drive system1700 comprises a rotatable shaft 1710 comprising a splined distal end1720 and a longitudinal aperture 1730 defined therein. The rotatableshaft 1710 is operably mounted to the output shaft of the motor assembly1600 such that the rotatable shaft 1710 rotates with the motor outputshaft. The handle frame 1510 extends through the longitudinal aperture1730 and rotatably supports the rotatable shaft 1710. As a result, thehandle frame 1510 serves as a bearing for the rotatable shaft 1710. Thehandle frame 1510 and the rotatable shaft 1710 extend distally from amounting interface 1130 of the drive module 1110 and are coupled withcorresponding components on the shaft assembly 2000 when the shaftassembly 2000 is assembled to the drive module 1100. Referring primarilyto FIGS. 3-6, the shaft assembly 2000 further comprises a frame 2500 anda drive system 2700. The frame 2500 comprises a longitudinal shaft 2510extending through the shaft assembly 2000 and a plurality of electricalcontacts, or pins, 2520 extending proximally from the shaft 2510. Whenthe shaft assembly 2000 is attached to the drive module 1100, theelectrical contacts 2520 on the shaft frame 2510 engage the electricalcontacts 1520 on the handle frame 1510 and create electrical pathwaystherebetween.

Similar to the above, the drive system 2700 comprises a rotatable driveshaft 2710 which is operably coupled to the rotatable drive shaft 1710of the handle 1000 when the shaft assembly 2000 is assembled to thedrive module 1100 such that the drive shaft 2710 rotates with the driveshaft 1710. To this end, the drive shaft 2710 comprises a splinedproximal end 2720 which mates with the splined distal end 1720 of thedrive shaft 1710 such that the drive shafts 1710 and 2710 rotatetogether when the drive shaft 1710 is rotated by the motor assembly1600. Given the nature of the splined interconnection between the driveshafts 1710 and 2710 and the electrical interconnection between theframes 1510 and 2510, the shaft assembly 2000 is assembled to the handle1000 along a longitudinal axis; however, the operable interconnectionbetween the drive shafts 1710 and 2710 and the electricalinterconnection between the frames 1510 and 2510 can comprise anysuitable configuration which can allow a shaft assembly to be assembledto the handle 1000 in any suitable manner.

As discussed above, referring to FIGS. 3-8, the mounting interface 1130of the drive module 1110 is configured to be coupled to a correspondingmounting interface on the shaft assemblies 2000, 3000, 4000, and 5000,for example. For instance, the shaft assembly 2000 comprises a mountinginterface 2130 configured to be coupled to the mounting interface 1130of the drive module 1100. More specifically, the proximal portion 2100of the shaft assembly 2000 comprises a housing 2110 which defines themounting interface 2130. Referring primarily to FIG. 8, the drive module1100 comprises latches 1140 which are configured to releasably hold themounting interface 2130 of the shaft assembly 2000 against the mountinginterface 1130 of the drive module 1100. When the drive module 1100 andthe shaft assembly 2000 are brought together along a longitudinal axis,as described above, the latches 1140 contact the mounting interface 2130and rotate outwardly into an unlocked position. Referring primarily toFIGS. 8, 10, and 11, each latch 1140 comprises a lock end 1142 and apivot portion 1144. The pivot portion 1144 of each latch 1140 isrotatably coupled to the housing 1110 of the drive module 1100 and, whenthe latches 1140 are rotated outwardly, as mentioned above, the latches1140 rotate about the pivot portions 1144. Notably, each latch 1140further comprises a biasing spring 1146 configured to bias the latches1140 inwardly into a locked position. Each biasing spring 1146 iscompressed between a latch 1140 and the housing 1110 of the drive module1100 such that the biasing springs 1146 apply biasing forces to thelatches 1140; however, such biasing forces are overcome when the latches1140 are rotated outwardly into their unlocked positions by the shaftassembly 2000. That said, when the latches 1140 rotate outwardly aftercontacting the mounting interface 2130, the lock ends 1142 of thelatches 1140 can enter into latch windows 2140 defined in the mountinginterface 2130. Once the lock ends 1142 pass through the latch windows2140, the springs 1146 can bias the latches 1140 back into their lockedpositions. Each lock end 1142 comprises a lock shoulder, or surface,which securely holds the shaft assembly 2000 to the drive module 1100.

Further to the above, the biasing springs 1146 hold the latches 1140 intheir locked positions. The distal ends 1142 are sized and configured toprevent, or at least inhibit, relative longitudinal movement, i.e.,translation along a longitudinal axis, between the shaft assembly 2000and the drive module 1100 when the latches 1140 are in their lockedpositions. Moreover, the latches 1140 and the latch windows 1240 aresized and configured to prevent relative lateral movement, i.e.,translation transverse to the longitudinal axis, between the shaftassembly 2000 and the drive module 1100. In addition, the latches 1140and the latch windows 2140 are sized and configured to prevent the shaftassembly 2000 from rotating relative to the drive module 1100. The drivemodule 1100 further comprises release actuators 1150 which, whendepressed by a clinician, move the latches 1140 from their lockedpositions into their unlocked positions. The drive module 1100 comprisesa first release actuator 1150 slideably mounted in an opening defined inthe first side of the handle housing 1110 and a second release actuator1150 slideably mounted in an opening defined in a second, or opposite,side of the handle housing 1110. Although the release actuators 1150 areactuatable separately, both release actuators 1150 typically need to bedepressed to completely unlock the shaft assembly 2000 from the drivemodule 1100 and allow the shaft assembly 2000 to be detached from thedrive module 1100. That said, it is possible that the shaft assembly2000 could be detached from the drive module 1100 by depressing only onerelease actuator 1150.

Once the shaft assembly 2000 has been secured to the handle 1000 and theend effector 7000, for example, has been assembled to the shaft 2000,the clinician can maneuver the handle 1000 to insert the end effector7000 into a patient. In at least one instance, the end effector 7000 isinserted into the patient through a trocar and then manipulated in orderto position the jaw assembly 7100 of the end effector assembly 7000relative to the patient's tissue. Oftentimes, the jaw assembly 7100 mustbe in its closed, or clamped, configuration in order to fit through thetrocar. Once through the trocar, the jaw assembly 7100 can be opened sothat the patient tissue fit between the jaws of the jaw assembly 7100.At such point, the jaw assembly 7100 can be returned to its closedconfiguration to clamp the patient tissue between the jaws. The clampingforce applied to the patient tissue by the jaw assembly 7100 issufficient to move or otherwise manipulate the tissue during a surgicalprocedure. Thereafter, the jaw assembly 7100 can be re-opened to releasethe patient tissue from the end effector 7000. This process can berepeated until it is desirable to remove the end effector 7000 from thepatient. At such point, the jaw assembly 7100 can be returned to itsclosed configuration and retracted through the trocar. Other surgicaltechniques are envisioned in which the end effector 7000 is insertedinto a patient through an open incision, or without the use of thetrocar. In any event, it is envisioned that the jaw assembly 7100 mayhave to be opened and closed several times throughout a surgicaltechnique.

Referring again to FIGS. 3-6, the shaft assembly 2000 further comprisesa clamping trigger system 2600 and a control system 2800. The clampingtrigger system 2600 comprises a clamping trigger 2610 rotatablyconnected to the proximal housing 2110 of the shaft assembly 2000. Asdiscussed below, the clamping trigger 2610 actuates the motor 1610 tooperate the jaw drive of the end effector 7000 when the clamping trigger2610 is actuated. The clamping trigger 2610 comprises an elongateportion which is graspable by the clinician while holding the handle1000. The clamping trigger 2610 further comprises a mounting portion2620 which is pivotably connected to a mounting portion 2120 of theproximal housing 2110 such that the clamping trigger 2610 is rotatableabout a fixed, or an at least substantially fixed, axis. The closuretrigger 2610 is rotatable between a distal position and a proximalposition, wherein the proximal position of the closure trigger 2610 iscloser to the pistol grip of the handle 1000 than the distal position.The closure trigger 2610 further comprises a tab 2615 extendingtherefrom which rotates within the proximal housing 2110. When theclosure trigger 2610 is in its distal position, the tab 2615 ispositioned above, but not in contact with, a switch 2115 mounted on theproximal housing 2110. The switch 2115 is part of an electrical circuitconfigured to detect the actuation of the closure trigger 2610 which isin an open condition the closure trigger 2610 is in its open position.When the closure trigger 2610 is moved into its proximal position, thetab 2615 comes into contact with the switch 2115 and closes theelectrical circuit. In various instances, the switch 2115 can comprise atoggle switch, for example, which is mechanically switched between openand closed states when contacted by the tab 2615 of the closure trigger2610. In certain instances, the switch 2115 can comprise a proximitysensor, for example, and/or any suitable type of sensor. In at least oneinstance, the switch 2115 comprises a Hall Effect sensor which candetect the amount in which the closure trigger 2610 has been rotatedand, based on the amount of rotation, control the speed in which themotor 1610 is operated. In such instances, larger rotations of theclosure trigger 2610 result in faster speeds of the motor 1610 whilesmaller rotations result in slower speeds, for example. In any event,the electrical circuit is in communication with the control system 2800of the shaft assembly 2000, which is discussed in greater detail below.

Further to the above, the control system 2800 of the shaft assembly 2000comprises a printed circuit board (PCB) 2810, at least onemicroprocessor 2820, and at least one memory device 2830. The board 2810can be rigid and/or flexible and can comprise any suitable number oflayers. The microprocessor 2820 and the memory device 2830 are part of acontrol circuit defined on the board 2810 which communicates with thecontrol system 1800 of the handle 1000. The shaft assembly 2000 furthercomprises a signal communication system 2900 and the handle 1000 furthercomprises a signal communication system 1900 which are configured toconvey data between the shaft control system 2800 and the handle controlsystem 1800. The signal communication system 2900 is configured totransmit data to the signal communication system 1900 utilizing anysuitable analog and/or digital components. In various instances, thecommunication systems 2900 and 1900 can communicate using a plurality ofdiscrete channels which allows the input gates of the microprocessor1820 to be directly controlled, at least in part, by the output gates ofthe microprocessor 2820. In some instances, the communication systems2900 and 1900 can utilize multiplexing. In at least one such instance,the control system 2900 includes a multiplexing device that sendsmultiple signals on a carrier channel at the same time in the form of asingle, complex signal to a multiplexing device of the control system1900 that recovers the separate signals from the complex signal.

The communication system 2900 comprises an electrical connector 2910mounted to the circuit board 2810. The electrical connector 2910comprises a connector body and a plurality of electrically-conductivecontacts mounted to the connector body. The electrically-conductivecontacts comprise male pins, for example, which are soldered toelectrical traces defined in the circuit board 2810. In other instances,the male pins can be in communication with circuit board traces throughzero-insertion-force (ZIF) sockets, for example. The communicationsystem 1900 comprises an electrical connector 1910 mounted to thecircuit board 1810. The electrical connector 1910 comprises a connectorbody and a plurality of electrically-conductive contacts mounted to theconnector body. The electrically-conductive contacts comprise femalepins, for example, which are soldered to electrical traces defined inthe circuit board 1810. In other instances, the female pins can be incommunication with circuit board traces through zero-insertion-force(ZIF) sockets, for example. When the shaft assembly 2000 is assembled tothe drive module 1100, the electrical connector 2910 is operably coupledto the electrical connector 1910 such that the electrical contacts formelectrical pathways therebetween. The above being said, the connectors1910 and 2910 can comprise any suitable electrical contacts. Moreover,the communication systems 1900 and 2900 can communicate with one anotherin any suitable manner. In various instances, the communication systems1900 and 2900 communicate wirelessly. In at least one such instance, thecommunication system 2900 comprises a wireless signal transmitter andthe communication system 1900 comprises a wireless signal receiver suchthat the shaft assembly 2000 can wirelessly communicate data to thehandle 1000. Likewise, the communication system 1900 can comprise awireless signal transmitter and the communication system 2900 cancomprise a wireless signal receiver such that the handle 1000 canwirelessly communicate data to the shaft assembly 2000.

As discussed above, the control system 1800 of the handle 1000 is incommunication with, and is configured to control, the electrical powercircuit of the handle 1000. The handle control system 1800 is alsopowered by the electrical power circuit of the handle 1000. The handlecommunication system 1900 is in signal communication with the handlecontrol system 1800 and is also powered by the electrical power circuitof the handle 1000. The handle communication system 1900 is powered bythe handle electrical power circuit via the handle control system 1800,but could be directly powered by the electrical power circuit. As alsodiscussed above, the handle communication system 1900 is in signalcommunication with the shaft communication system 2900. That said, theshaft communication system 2900 is also powered by the handle electricalpower circuit via the handle communication system 1900. To this end, theelectrical connectors 1910 and 2010 connect both one or more signalcircuits and one or more power circuits between the handle 1000 and theshaft assembly 2000. Moreover, the shaft communication system 2900 is insignal communication with the shaft control system 2800, as discussedabove, and is also configured to supply power to the shaft controlsystem 2800. Thus, the control systems 1800 and 2800 and thecommunication systems 1900 and 2900 are all powered by the electricalpower circuit of the handle 1000; however, alternative embodiments areenvisioned in which the shaft assembly 2000 comprises its own powersource, such as one or more batteries, for example, an and electricalpower circuit configured to supply power from the batteries to thehandle systems 2800 and 2900. In at least one such embodiment, thehandle control system 1800 and the handle communication system 1900 arepowered by the handle electrical power system and the shaft controlsystem 2800 and the handle communication system 2900 are powered by theshaft electrical power system.

Further to the above, the actuation of the clamping trigger 2610 isdetected by the shaft control system 2800 and communicated to the handlecontrol system 1800 via the communication systems 2900 and 1900. Uponreceiving a signal that the clamping trigger 2610 has been actuated, thehandle control system 1800 supplies power to the electric motor 1610 ofthe motor assembly 1600 to rotate the drive shaft 1710 of the handledrive system 1700, and the drive shaft 2710 of the shaft drive system2700, in a direction which closes the jaw assembly 7100 of the endeffector 7000. The mechanism for converting the rotation of the driveshaft 2710 to a closure motion of the jaw assembly 7100 is discussed ingreater detail below. So long as the clamping trigger 2610 is held inits actuated position, the electric motor 1610 will rotate the driveshaft 1710 until the jaw assembly 7100 reaches its fully-clampedposition. When the jaw assembly 7100 reaches its fully-clamped position,the handle control system 1800 cuts the electrical power to the electricmotor 1610. The handle control system 1800 can determine when the jawassembly 7100 has reached its fully-clamped position in any suitablemanner. For instance, the handle control system 1800 can comprise anencoder system which monitors the rotation of, and counts the rotationsof, the output shaft of the electric motor 1610 and, once the number ofrotations reaches a predetermined threshold, the handle control system1800 can discontinue supplying power to the electric motor 1610. In atleast one instance, the end effector assembly 7000 can comprise one ormore sensors configured to detect when the jaw assembly 7100 has reachedits fully-clamped position. In at least one such instance, the sensorsin the end effector 7000 are in signal communication with the handlecontrol system 1800 via electrical circuits extending through the shaftassembly 2000 which can include the electrical contacts 1520 and 2520,for example.

When the clamping trigger 2610 is rotated distally out of its proximalposition, the switch 2115 is opened which is detected by the shaftcontrol system 2800 and communicated to the handle control system 1800via the communication systems 2900 and 1900. Upon receiving a signalthat the clamping trigger 2610 has been moved out of its actuatedposition, the handle control system 1800 reverses the polarity of thevoltage differential being applied to the electric motor 1610 of themotor assembly 1600 to rotate the drive shaft 1710 of the handle drivesystem 1700, and the drive shaft 2710 of the shaft drive system 2700, inan opposite direction which, as a result, opens the jaw assembly 7100 ofthe end effector 7000. When the jaw assembly 7100 reaches its fully-openposition, the handle control system 1800 cuts the electrical power tothe electric motor 1610. The handle control system 1800 can determinewhen the jaw assembly 7100 has reached its fully-open position in anysuitable manner. For instance, the handle control system 1800 canutilize the encoder system and/or the one or more sensors describedabove to determine the configuration of the jaw assembly 7100. In viewof the above, the clinician needs to be mindful about holding theclamping trigger 2610 in its actuated position in order to maintain thejaw assembly 7100 in its clamped configuration as, otherwise, thecontrol system 1800 will open jaw assembly 7100. With this in mind, theshaft assembly 2000 further comprises an actuator latch 2630 configuredto releasably hold the clamping trigger 2610 in its actuated position toprevent the accidental opening of the jaw assembly 7100. The actuatorlatch 2630 can be manually released, or otherwise defeated, by theclinician to allow the clamping trigger 2610 to be rotated distally andopen the jaw assembly 7100.

The clamping trigger system 2600 further comprises a resilient biasingmember, such as a torsion spring, for example, configured to resist theclosure of the clamping trigger system 2600. The torsion spring can alsoassist in reducing and/or mitigating sudden movements and/or jitter ofthe clamping trigger 2610. Such a torsion spring can also automaticallyreturn the clamping trigger 2610 to its unactuated position when theclamping trigger 2610 is released. The actuator latch 2630 discussedabove can suitably hold the clamping trigger 2610 in its actuatedposition against the biasing force of the torsion spring.

As discussed above, the control system 1800 operates the electric motor1610 to open and close the jaw assembly 7100. The control system 1800 isconfigured to open and close the jaw assembly 7100 at the same speed. Insuch instances, the control system 1800 applies the same voltage pulsesto the electric motor 1610, albeit with different voltage polarities,when opening and closing the jaw assembly 7100. That said, the controlsystem 1800 can be configured to open and close the jaw assembly 7100 atdifferent speeds. For instance, the jaw assembly 7100 can be closed at afirst speed and opened at a second speed which is faster than the firstspeed. In such instances, the slower closing speed affords the clinicianan opportunity to better position the jaw assembly 7100 while clampingthe tissue. Alternatively, the control system 1800 can open the jawassembly 7100 at a slower speed. In such instances, the slower openingspeed reduces the possibility of the opening jaws colliding withadjacent tissue. In either event, the control system 1800 can decreasethe duration of the voltage pulses and/or increase the duration betweenthe voltage pulses to slow down and/or speed up the movement of the jawassembly 7100.

As discussed above, the control system 1800 is configured to interpretthe position of the clamping trigger 2610 as a command to position thejaw assembly 7100 in a specific configuration. For instance, the controlsystem 1800 is configured to interpret the proximal-most position of theclamping trigger 2610 as a command to close the jaw assembly 7100 andany other position of the clamping trigger as a command to open the jawassembly 7100. That said, the control system 1800 can be configured tointerpret the position of the clamping trigger 2610 in a proximal rangeof positions, instead of a single position, as a command to close thejaw assembly 7100. Such an arrangement can allow the jaw assembly 7000to be better responsive to the clinician's input. In such instances, therange of motion of the clamping trigger 2610 is divided into ranges—aproximal range which is interpreted as a command to close the jawassembly 7100 and a distal range which is interpreted as a command toopen the jaw assembly 7100. In at least one instance, the range ofmotion of the clamping trigger 2610 can have an intermediate rangebetween the proximal range and the distal range. When the clampingtrigger 2610 is in the intermediate range, the control system 1800 caninterpret the position of the clamping trigger 2610 as a command toneither open nor close the jaw assembly 7100. Such an intermediate rangecan prevent, or reduce the possibility of, jitter between the openingand closing ranges. In the instances described above, the control system1800 can be configured to ignore cumulative commands to open or closethe jaw assembly 7100. For instance, if the closure trigger 2610 hasalready been fully retracted into its proximal-most position, thecontrol assembly 1800 can ignore the motion of the clamping trigger 2610in the proximal, or clamping, range until the clamping trigger 2610enters into the distal, or opening, range wherein, at such point, thecontrol system 1800 can then actuate the electric motor 1610 to open thejaw assembly 7100.

In certain instances, further to the above, the position of the clampingtrigger 2610 within the clamping trigger range, or at least a portion ofthe clamping trigger range, can allow the clinician to control the speedof the electric motor 1610 and, thus, the speed in which the jawassembly 7100 is being opened or closed by the control assembly 1800. Inat least one instance, the sensor 2115 comprises a Hall Effect sensor,and/or any other suitable sensor, configured to detect the position ofthe clamping trigger 2610 between its distal, unactuated position andits proximal, fully-actuated position. The Hall Effect sensor isconfigured to transmit a signal to the handle control system 1800 viathe shaft control system 2800 such that the handle control system 1800can control the speed of the electric motor 1610 in response to theposition of the clamping trigger 2610. In at least one instance, thehandle control system 1800 controls the speed of the electric motor 1610proportionately, or in a linear manner, to the position of the clampingtrigger 2610. For example, if the clamping trigger 2610 is moved halfway through its range, then the handle control system 1800 will operatethe electric motor 1610 at half of the speed in which the electric motor1610 is operated when the clamping trigger 2610 is fully-retracted.Similarly, if the clamping trigger 2610 is moved a quarter way throughits range, then the handle control system 1800 will operate the electricmotor 1610 at a quarter of the speed in which the electric motor 1610 isoperated when the clamping trigger 2610 is fully-retracted. Otherembodiments are envisioned in which the handle control system 1800controls the speed of the electric motor 1610 in a non-linear manner tothe position of the clamping trigger 2610. In at least one instance, thecontrol system 1800 operates the electric motor 1610 slowly in thedistal portion of the clamping trigger range while quickly acceleratingthe speed of the electric motor 1610 in the proximal portion of theclamping trigger range.

As described above, the clamping trigger 2610 is movable to operate theelectric motor 1610 to open or close the jaw assembly 7100 of the endeffector 7000. The electric motor 1610 is also operable to rotate theend effector 7000 about a longitudinal axis and articulate the endeffector 7000 relative to the elongate shaft 2200 about the articulationjoint 2300 of the shaft assembly 2000. Referring primarily to FIGS. 7and 8, the drive module 1100 comprises an input system 1400 including arotation actuator 1420 and an articulation actuator 1430. The inputsystem 1400 further comprises a printed circuit board (PCB) 1410 whichis in signal communication with the printed circuit board (PCB) 1810 ofthe control system 1800. The drive module 1100 comprises an electricalcircuit, such as a flexible wiring harness or ribbon, for example, whichpermits the input system 1400 to communicate with the control system1800. The rotation actuator 1420 is rotatably supported on the housing1110 and is in signal communication with the input board 1410 and/orcontrol board 1810, as described in greater detail below. Thearticulation actuator 1430 is supported by and in signal communicationwith the input board 1410 and/or control board 1810, as also describedin greater detail below.

Referring primarily to FIGS. 8, 10, and 11, further to the above, thehandle housing 1110 comprises an annular groove or slot defined thereinadjacent the distal mounting interface 1130. The rotation actuator 1420comprises an annular ring 1422 rotatably supported within the annulargroove and, owing to the configuration of the sidewalls of the annulargroove, the annular ring 1422 is constrained from translatinglongitudinally and/or laterally with respect to the handle housing 1110.The annular ring 1422 is rotatable in a first, or clockwise, directionand a second, or counter-clockwise direction, about a longitudinal axisextending through the frame 1500 of the drive module 1100. The rotationactuator 1420 comprises one or more sensors configured to detect therotation of the annular ring 1422. In at least one instance, therotation actuator 1420 comprises a first sensor positioned on a firstside of the drive module 1100 and a second sensor positioned on asecond, or opposite, side of the drive module 1100 and the annular ring1422 comprises a detectable element which is detectable by the first andsecond sensors. The first sensor is configured to detect when theannular ring 1422 is rotated in the first direction and the secondsensor is configured to detect when the annular ring 1422 is rotated inthe second direction. When the first sensor detects that the annularring 1422 is rotated in the first direction, the handle control system1800 rotates the handle drive shaft 1710, the drive shaft 2710, and theend effector 7000 in the first direction, as described in greater detailbelow. Similarly, the handle control system 1800 rotates the handledrive shaft 1710, the drive shaft 2710, and the end effector 7000 in thesecond direction when the second sensor detects that the annular ring1422 is rotated in the second direction. In view of the above, thereader should appreciate that the clamping trigger 2610 and the rotationactuator 1420 are both operable to rotate the drive shaft 2710.

In various embodiments, further to the above, the first and secondsensors comprise switches which are mechanically closable by thedetectable element of the annular ring 1422. When the annular ring 1422is rotated in the first direction from a center position, the detectableelement closes the switch of the first sensor. When the switch of thefirst sensor is closed, the control system 1800 operates the electricmotor 1610 to rotate the end effector 7000 in the first direction. Whenthe annular ring 1422 is rotated in the second direction toward thecenter position, the detectable element is disengaged from the firstswitch and the first switch is re-opened. Once the first switch isre-opened, the control system 1800 cuts the power to the electric motor1610 to stop the rotation of the end effector 7000. Similarly, thedetectable element closes the switch of the second sensor when theannular ring 1422 is rotated in the second direction from the centerposition. When the switch of the second sensor is closed, the controlsystem 1800 operates the electric motor 1610 to rotate the end effector7000 in the second direction. When the annular ring 1422 is rotated inthe first direction toward the center position, the detectable elementis disengaged from the second switch and the second switch is re-opened.Once the second switch is re-opened, the control system 1800 cuts thepower to the electric motor 1610 to stop the rotation of the endeffector 7000.

In various embodiments, further to the above, the first and secondsensors of the rotation actuator 1420 comprise proximity sensors, forexample. In certain embodiments, the first and second sensors of therotation actuator 1420 comprise Hall Effect sensors, and/or any suitablesensors, configured to detect the distance between the detectableelement of the annular ring 1422 and the first and second sensors. Ifthe first Hall Effect sensor detects that the annular ring 1422 has beenrotated in the first direction, then, as discussed above, the controlsystem 1800 will rotate the end effector 7000 in the first direction. Inaddition, the control system 1800 can rotate the end effector 7000 at afaster speed when the detectable element is closer to the first HallEffect sensor than when the detectable element is further away from thefirst Hall Effect sensor. If the second Hall Effect sensor detects thatthe annular ring 1422 has been rotated in the second direction, then, asdiscussed above, the control system 1800 will rotate the end effector7000 in the second direction. In addition, the control system 1800 canrotate the end effector 7000 at a faster speed when the detectableelement is closer to the second Hall Effect sensor than when thedetectable element is further away from the second Hall Effect sensor.As a result, the speed in which the end effector 7000 is rotated is afunction of the amount, or degree, in which the annular ring 1422 isrotated. The control system 1800 is further configured to evaluate theinputs from both the first and second Hall Effect sensors whendetermining the direction and speed in which to rotate the end effector7000. In various instances, the control system 1800 can use the closestHall Effect sensor to the detectable element of the annular ring 1422 asa primary source of data and the Hall Effect sensor furthest away fromthe detectable element as a conformational source of data todouble-check the data provided by the primary source of data. Thecontrol system 1800 can further comprise a data integrity protocol toresolve situations in which the control system 1800 is provided withconflicting data. In any event, the handle control system 1800 can enterinto a neutral state in which the handle control system 1800 does notrotate the end effector 7000 when the Hall Effect sensors detect thatthe detectable element is in its center position, or in a position whichis equidistant between the first Hall Effect sensor and the second HallEffect sensor. In at least one such instance, the control system 1800can enter into its neutral state when the detectable element is in acentral range of positions. Such an arrangement would prevent, or atleast reduce the possibility of, rotational jitter when the clinician isnot intending to rotate the end effector 7000.

Further to the above, the rotation actuator 1420 can comprise one ormore springs configured to center, or at least substantially center, therotation actuator 1420 when it is released by the clinician. In suchinstances, the springs can act to shut off the electric motor 1610 andstop the rotation of the end effector 7000. In at least one instance,the rotation actuator 1420 comprises a first torsion spring configuredto rotate the rotation actuator 1420 in the first direction and a secondtorsion spring configured to rotate the rotation actuator 1420 in thesecond direction. The first and second torsion springs can have thesame, or at least substantially the same, spring constant such that theforces and/or torques applied by the first and second torsion springsbalance, or at least substantially balance, the rotation actuator 1420in its center position.

In view of the above, the reader should appreciate that the clampingtrigger 2610 and the rotation actuator 1420 are both operable to rotatethe drive shaft 2710 and either, respectively, operate the jaw assembly7100 or rotate the end effector 7000. The system that uses the rotationof the drive shaft 2710 to selectively perform these functions isdescribed in greater detail below.

Referring to FIGS. 7 and 8, the articulation actuator 1430 comprises afirst push button 1432 and a second push button 1434. The first pushbutton 1432 is part of a first articulation control circuit and thesecond push button 1434 is part of a second articulation circuit of theinput system 1400. The first push button 1432 comprises a first switchthat is closed when the first push button 1432 is depressed. The handlecontrol system 1800 is configured to sense the closure of the firstswitch and, moreover, the closure of the first articulation controlcircuit. When the handle control system 1800 detects that the firstarticulation control circuit has been closed, the handle control system1800 operates the electric motor 1610 to articulate the end effector7000 in a first articulation direction about the articulation joint2300. When the first push button 1432 is released by the clinician, thefirst articulation control circuit is opened which, once detected by thecontrol system 1800, causes the control system 1800 to cut the power tothe electric motor 1610 to stop the articulation of the end effector7000.

In various instances, further to the above, the articulation range ofthe end effector 7000 is limited and the control system 1800 can utilizethe encoder system discussed above for monitoring the rotational outputof the electric motor 1610, for example, to monitor the amount, ordegree, in which the end effector 7000 is rotated in the firstdirection. In addition to or in lieu of the encoder system, the shaftassembly 2000 can comprise a first sensor configured to detect when theend effector 7000 has reached the limit of its articulation in the firstdirection. In any event, when the control system 1800 determines thatthe end effector 7000 has reached the limit of articulation in the firstdirection, the control system 1800 can cut the power to the electricmotor 1610 to stop the articulation of the end effector 7000.

Similar to the above, the second push button 1434 comprises a secondswitch that is closed when the second push button 1434 is depressed. Thehandle control system 1800 is configured to sense the closure of thesecond switch and, moreover, the closure of the second articulationcontrol circuit. When the handle control system 1800 detects that thesecond articulation control circuit has been closed, the handle controlsystem 1800 operates the electric motor 1610 to articulate the endeffector 7000 in a second direction about the articulation joint 2300.When the second push button 1434 is released by the clinician, thesecond articulation control circuit is opened which, once detected bythe control system 1800, causes the control system 1800 to cut the powerto the electric motor 1610 to stop the articulation of the end effector7000.

In various instances, the articulation range of the end effector 7000 islimited and the control system 1800 can utilize the encoder systemdiscussed above for monitoring the rotational output of the electricmotor 1610, for example, to monitor the amount, or degree, in which theend effector 7000 is rotated in the second direction. In addition to orin lieu of the encoder system, the shaft assembly 2000 can comprise asecond sensor configured to detect when the end effector 7000 hasreached the limit of its articulation in the second direction. In anyevent, when the control system 1800 determines that the end effector7000 has reached the limit of articulation in the second direction, thecontrol system 1800 can cut the power to the electric motor 1610 to stopthe articulation of the end effector 7000.

As described above, the end effector 7000 is articulatable in a firstdirection (FIG. 16) and/or a second direction (FIG. 17) from a center,or unarticulated, position (FIG. 15). Once the end effector 7000 hasbeen articulated, the clinician can attempt to re-center the endeffector 7000 by using the first and second articulation push buttons1432 and 1434. As the reader can appreciate, the clinician may struggleto re-center the end effector 7000 as, for instance, the end effector7000 may not be entirely visible once it is positioned in the patient.In some instances, the end effector 7000 may not fit back through atrocar if the end effector 7000 is not re-centered, or at leastsubstantially re-centered. With that in mind, the control system 1800 isconfigured to provide feedback to the clinician when the end effector7000 is moved into its unarticulated, or centered, position. In at leastone instance, the feedback comprises audio feedback and the handlecontrol system 1800 can comprise a speaker which emits a sound, such asa beep, for example, when the end effector 7000 is centered. In certaininstances, the feedback comprises visual feedback and the handle controlsystem 1800 can comprise a light emitting diode (LED), for example,positioned on the handle housing 1110 which flashes when the endeffector 7000 is centered. In various instances, the feedback compriseshaptic feedback and the handle control system 1800 can comprise anelectric motor comprising an eccentric element which vibrates the handle1000 when the end effector 7000 is centered. Manually re-centering theend effector 7000 in this way can be facilitated by the control system1800 slowing the motor 1610 when the end effector 7000 is approachingits centered position. In at least one instance, the control system 1800slows the articulation of the end effector 7000 when the end effector7000 is within approximately 5 degrees of center in either direction,for example.

In addition to or in lieu of the above, the handle control system 1800can be configured to re-center the end effector 7000. In at least onesuch instance, the handle control system 1800 can re-center the endeffector 7000 when both of the articulation buttons 1432 and 1434 of thearticulation actuator 1430 are depressed at the same time. When thehandle control system 1800 comprises an encoder system configured tomonitor the rotational output of the electric motor 1610, for example,the handle control system 1800 can determine the amount and direction ofarticulation needed to re-center, or at least substantially re-center,the end effector 7000. In various instances, the input system 1400 cancomprise a home button, for example, which, when depressed,automatically centers the end effector 7000.

Referring primarily to FIGS. 5 and 6, the elongate shaft 2200 of theshaft assembly 2000 comprises an outer housing, or tube, 2210 mounted tothe proximal housing 2110 of the proximal portion 2100. The outerhousing 2210 comprises a longitudinal aperture 2230 extendingtherethrough and a proximal flange 2220 which secures the outer housing2210 to the proximal housing 2110. The frame 2500 of the shaft assembly2000 extends through the longitudinal aperture 2230 of the elongateshaft 2200. More specifically, the shaft 2510 of the shaft frame 2500necks down into a smaller shaft 2530 which extends through thelongitudinal aperture 2230. That said, the shaft frame 2500 can compriseany suitable arrangement. The drive system 2700 of the shaft assembly2000 also extends through the longitudinal aperture 2230 of the elongateshaft 2200. More specifically, the drive shaft 2710 of the shaft drivesystem 2700 necks down into a smaller drive shaft 2730 which extendsthrough the longitudinal aperture 2230. That said, the shaft drivesystem 2700 can comprise any suitable arrangement.

Referring primarily to FIGS. 20, 23, and 24, the outer housing 2210 ofthe elongate shaft 2200 extends to the articulation joint 2300. Thearticulation joint 2300 comprises a proximal frame 2310 mounted to theouter housing 2210 such that there is little, if any, relativetranslation and/or rotation between the proximal frame 2310 and theouter housing 2210. Referring primarily to FIG. 22, the proximal frame2310 comprises an annular portion 2312 mounted to the sidewall of theouter housing 2210 and tabs 2314 extending distally from the annularportion 2312. The articulation joint 2300 further comprises links 2320and 2340 which are rotatably mounted to the frame 2310 and mounted to anouter housing 2410 of the distal attachment portion 2400. The link 2320comprises a distal end 2322 mounted to the outer housing 2410. Morespecifically, the distal end 2322 of the link 2320 is received andfixedly secured within a mounting slot 2412 defined in the outer housing2410. Similarly, the link 2340 comprises a distal end 2342 mounted tothe outer housing 2410. More specifically, the distal end 2342 of thelink 2340 is received and fixedly secured within a mounting slot definedin the outer housing 2410. The link 2320 comprises a proximal end 2324rotatably coupled to a tab 2314 of the proximal articulation frame 2310.Although not illustrated in FIG. 22, a pin extends through aperturesdefined in the proximal end 2324 and the tab 2314 to define a pivot axistherebetween. Similarly, the link 2340 comprises a proximal end 2344rotatably coupled to a tab 2314 of the proximal articulation frame 2310.Although not illustrated in FIG. 22, a pin extends through aperturesdefined in the proximal end 2344 and the tab 2314 to define a pivot axistherebetween. These pivot axes are collinear, or at least substantiallycollinear, and define an articulation axis A of the articulation joint2300.

Referring primarily to FIGS. 20, 23, and 24, the outer housing 2410 ofthe distal attachment portion 2400 comprises a longitudinal aperture2430 extending therethrough. The longitudinal aperture 2430 isconfigured to receive a proximal attachment portion 7400 of the endeffector 7000. The end effector 7000 comprises an outer housing 6230which is closely received within the longitudinal aperture 2430 of thedistal attachment portion 2400 such that there is little, if any,relative radial movement between the proximal attachment portion 7400 ofthe end effector 7000 and the distal attachment portion 2400 of theshaft assembly 2000. The proximal attachment portion 7400 furthercomprises an annular array of lock notches 7410 defined on the outerhousing 6230 which is releasably engaged by an end effector lock 6400 inthe distal attachment portion 2400 of the shaft assembly 2000. When theend effector lock 6400 is engaged with the array of lock notches 7410,the end effector lock 6400 prevents, or at least inhibits, relativelongitudinal movement between the proximal attachment portion 7400 ofthe end effector 7000 and the distal attachment portion 2400 of theshaft assembly 2000. As a result of the above, only relative rotationbetween the proximal attachment portion 7400 of the end effector 7000and the distal attachment portion 2400 of the shaft assembly 2000 ispermitted. To this end, the outer housing 6230 of the end effector 7000is closely received within the longitudinal aperture 2430 defined in thedistal attachment portion 2400 of the shaft assembly 2000.

Further to the above, referring to FIG. 21, the outer housing 6230further comprises an annular slot, or recess, 6270 defined therein whichis configured to receive an O-ring 6275 therein. The O-ring 6275 iscompressed between the outer housing 6230 and the sidewall of thelongitudinal aperture 2430 when the end effector 7000 is inserted intothe distal attachment portion 2400. The O-ring 6275 is configured toresist, but permit, relative rotation between the end effector 7000 andthe distal attachment portion 2400 such that the O-ring 6275 canprevent, or reduce the possibility of, unintentional relative rotationbetween the end effector 7000 and the distal attachment portion 2400. Invarious instances, the O-ring 6275 can provide a seal between the endeffector 7000 and the distal attachment portion 2400 to prevent, or atleast reduce the possibility of, fluid ingress into the shaft assembly2000, for example.

Referring to FIGS. 14-21, the jaw assembly 7100 of the end effector 7000comprises a first jaw 7110 and a second jaw 7120. Each jaw 7110, 7120comprises a distal end which is configured to assist a clinician indissecting tissue with the end effector 7000. Each jaw 7110, 7120further comprises a plurality of teeth which are configured to assist aclinician in grasping and holding onto tissue with the end effector7000. Moreover, referring primarily to FIG. 21, each jaw 7110, 7120comprises a proximal end, i.e., proximal ends 7115, 7125, respectively,which rotatably connect the jaws 7110, 7120 together. Each proximal end7115, 7125 comprises an aperture extending therethrough which isconfigured to closely receive a pin 7130 therein. The pin 7130 comprisesa central body 7135 closely received within the apertures defined in theproximal ends 7115, 7125 of the jaws 7110, 7120 such that there islittle, if any, relative translation between the jaws 7110, 7120 and thepin 7130. The pin 7130 defines a jaw axis J about which the jaws 7110,7120 can be rotated and, also, rotatably mounts the jaws 7110, 7120 tothe outer housing 6230 of the end effector 7000. More specifically, theouter housing 6230 comprises distally-extending tabs 6235 havingapertures defined therein which are also configured to closely receivethe pin 7130 such that the jaw assembly 7100 does not translate relativeto a shaft portion 7200 of the end effector 7000. The pin 7130 furthercomprises enlarged ends which prevent the jaws 7110, 7120 from becomingdetached from the pin 7130 and also prevents the jaw assembly 7100 frombecoming detached from the shaft portion 7200. This arrangement definesa rotation joint 7300.

Referring primarily to FIGS. 21 and 23, the jaws 7110 and 7120 arerotatable between their open and closed positions by a jaw assemblydrive including drive links 7140, a drive nut 7150, and a drive screw6130. As described in greater detail below, the drive screw 6130 isselectively rotatable by the drive shaft 2730 of the shaft drive system2700. The drive screw 6130 comprises an annular flange 6132 which isclosely received within a slot, or groove, 6232 (FIG. 25) defined in theouter housing 6230 of the end effector 7000. The sidewalls of the slot6232 are configured to prevent, or at least inhibit, longitudinal and/orradial translation between the drive screw 6130 and the outer housing6230, but yet permit relative rotational motion between the drive screw6130 and the outer housing 6230. The drive screw 6130 further comprisesa threaded end 6160 which is threadably engaged with a threaded aperture7160 defined in the drive nut 7150. The drive nut 7150 is constrainedfrom rotating with the drive screw 6130 and, as a result, the drive nut7150 is translated when the drive screw 6130 is rotated. In use, thedrive screw 6130 is rotated in a first direction to displace the drivenut 7150 proximally and in a second, or opposite, direction to displacethe drive nut 7150 distally. The drive nut 7150 further comprises adistal end 7155 comprising an aperture defined therein which isconfigured to closely receive pins 7145 extending from the drive links7140. Referring primarily to FIG. 21, a first drive link 7140 isattached to one side of the distal end 7155 and a second drive link 7140is attached to the opposite side of the distal end 7155. The first drivelink 7140 comprises another pin 7145 extending therefrom which isclosely received in an aperture defined in the proximal end 7115 of thefirst jaw 7110 and, similarly, the second drive link 7140 comprisesanother pin extending therefrom which is closely received in an aperturedefined in the proximal end 7125 of the second jaw 7120. As a result ofthe above, the drive links 7140 operably connect the jaws 7110 and 7120to the drive nut 7150. When the drive nut 7150 is driven proximally bythe drive screw 6130, as described above, the jaws 7110, 7120 arerotated into the closed, or clamped, configuration. Correspondingly, thejaws 7110, 7120 are rotated into their open configuration when the drivenut 7150 is driven distally by the drive screw 6130.

As discussed above, the control system 1800 is configured to actuate theelectric motor 1610 to perform three different end effectorfunctions—clamping/opening the jaw assembly 7100 (FIGS. 14 and 15),rotating the end effector 7000 about a longitudinal axis (FIGS. 18 and19), and articulating the end effector 7000 about an articulation axis(FIGS. 16 and 17). Referring primarily to FIGS. 26 and 27, the controlsystem 1800 is configured to operate a transmission 6000 to selectivelyperform these three end effector functions. The transmission 6000comprises a first clutch system 6100 configured to selectively transmitthe rotation of the drive shaft 2730 to the drive screw 6130 of the endeffector 7000 to open or close the jaw assembly 7100, depending on thedirection in which the drive shaft 2730 is rotated. The transmission6000 further comprises a second clutch system 6200 configured toselectively transmit the rotation of the drive shaft 2730 to the outerhousing 6230 of the end effector 7000 to rotate the end effector 7000about the longitudinal axis L. The transmission 6000 also comprises athird clutch system 6300 configured to selectively transmit the rotationof the drive shaft 2730 to the articulation joint 2300 to articulate thedistal attachment portion 2400 and the end effector 7000 about thearticulation axis A. The clutch systems 6100, 6200, and 6300 are inelectrical communication with the control system 1800 via electricalcircuits extending through the shaft 2510, the connector pins 2520, theconnector pins 1520, and the shaft 1510, for example. In at least oneinstance, each of these clutch control circuits comprises two connectorpins 2520 and two connector pins 1520, for example.

In various instances, further to the above, the shaft 2510 and/or theshaft 1510 comprise a flexible circuit including electrical traces whichform part of the clutch control circuits. The flexible circuit cancomprise a ribbon, or substrate, with conductive pathways definedtherein and/or thereon. The flexible circuit can also comprise sensorsand/or any solid state component, such as signal smoothing capacitors,for example, mounted thereto. In at least one instance, each of theconductive pathways can comprise one or more signal smoothing capacitorswhich can, among other things, even out fluctuations in signalstransmitted through the conductive pathways. In various instances, theflexible circuit can be coated with at least one material, such as anelastomer, for example, which can seal the flexible circuit againstfluid ingress.

Referring primarily to FIG. 28, the first clutch system 6100 comprises afirst clutch 6110, an expandable first drive ring 6120, and a firstelectromagnetic actuator 6140. The first clutch 6110 comprises anannular ring and is slideably disposed on the drive shaft 2730. Thefirst clutch 6110 is comprised of a magnetic material and is movablebetween a disengaged, or unactuated, position (FIG. 28) and an engaged,or actuated, position (FIG. 29) by electromagnetic fields EF generatedby the first electromagnetic actuator 6140. In various instances, thefirst clutch 6110 is at least partially comprised of iron and/or nickel,for example. In at least one instance, the first clutch 6110 comprises apermanent magnet. As illustrated in FIG. 22A, the drive shaft 2730comprises one or more longitudinal key slots 6115 defined therein whichare configured to constrain the longitudinal movement of the clutch 6110relative to the drive shaft 2730. More specifically, the clutch 6110comprises one or more keys extending into the key slots 6115 such thatthe distal ends of the key slots 6115 stop the distal movement of theclutch 6110 and the proximal ends of the key slots 6115 stop theproximal movement of the clutch 6110.

When the first clutch 6110 is in its disengaged position (FIG. 28), thefirst clutch 6110 rotates with the drive shaft 2130 but does nottransmit rotational motion to the first drive ring 6120. As can be seenin FIG. 28, the first clutch 6110 is separated from, or not in contactwith, the first drive ring 6120. As a result, the rotation of the driveshaft 2730 and the first clutch 6110 is not transmitted to the drivescrew 6130 when the first clutch assembly 6100 is in its disengagedstate. When the first clutch 6110 is in its engaged position (FIG. 29),the first clutch 6110 is engaged with the first drive ring 6120 suchthat the first drive ring 6120 is expanded, or stretched, radiallyoutwardly into contact with the drive screw 6130. In at least oneinstance, the first drive ring 6120 comprises an elastomeric band, forexample. As can be seen in FIG. 29, the first drive ring 6120 iscompressed against an annular inner sidewall 6135 of the drive screw6130. As a result, the rotation of the drive shaft 2730 and the firstclutch 6110 is transmitted to the drive screw 6130 when the first clutchassembly 6100 is in its engaged state. Depending on the direction inwhich the drive shaft 2730 is rotated, the first clutch assembly 6100can move the jaw assembly 7100 into its open and closed configurationswhen the first clutch assembly 6100 is in its engaged state.

As described above, the first electromagnetic actuator 6140 isconfigured to generate magnetic fields to move the first clutch 6110between its disengaged (FIG. 28) and engaged (FIG. 29) positions. Forinstance, referring to FIG. 28, the first electromagnetic actuator 6140is configured to emit a magnetic field EF_(L) which repulses, or drives,the first clutch 6110 away from the first drive ring 6120 when the firstclutch assembly 6100 is in its disengaged state. The firstelectromagnetic actuator 6140 comprises one or more wound coils in acavity defined in the shaft frame 2530 which generate the magnetic fieldEF_(L) when current flows in a first direction through a firstelectrical clutch circuit including the wound coils. The control system1800 is configured to apply a first voltage polarity to the firstelectrical clutch circuit to create the current flowing in the firstdirection. The control system 1800 can continuously apply the firstvoltage polarity to the first electric shaft circuit to continuouslyhold the first clutch 6110 in its disengaged position. While such anarrangement can prevent the first clutch 6110 from unintentionallyengaging the first drive ring 6120, such an arrangement can also consumea lot of power. Alternatively, the control system 1800 can apply thefirst voltage polarity to the first electrical clutch circuit for asufficient period of time to position the first clutch 6110 in itsdisengaged position and then discontinue applying the first voltagepolarity to the first electric clutch circuit, thereby resulting in alower consumption of power. That being said, the first clutch assembly6100 further comprises a first clutch lock 6150 mounted in the drivescrew 6130 which is configured to releasably hold the first clutch 6110in its disengaged position. The first clutch lock 6150 is configured toprevent, or at least reduce the possibility of, the first clutch 6110from becoming unintentionally engaged with the first drive ring 6120.When the first clutch 6110 is in its disengaged position, as illustratedin FIG. 28, the first clutch lock 6150 interferes with the free movementof the first clutch 6110 and holds the first clutch 6110 in position viaa friction force and/or an interference force therebetween. In at leastone instance, the first clutch lock 6150 comprises an elastomeric plug,seat, or detent, comprised of rubber, for example. In certain instances,the first clutch lock 6150 comprises a permanent magnet which holds thefirst clutch 6110 in its disengaged position by an electromagneticforce. In any event, the first electromagnetic actuator 6140 can applyan electromagnetic pulling force to the first clutch 6110 that overcomesthese forces, as described in greater detail below.

Further to the above, referring to FIG. 29, the first electromagneticactuator 6140 is configured to emit a magnetic field EF_(D) which pulls,or drives, the first clutch 6110 toward the first drive ring 6120 whenthe first clutch assembly 6100 is in its engaged state. The coils of thefirst electromagnetic actuator 6140 generate the magnetic field EF_(D)when current flows in a second, or opposite, direction through the firstelectrical clutch circuit. The control system 1800 is configured toapply an opposite voltage polarity to the first electrical clutchcircuit to create the current flowing in the opposite direction. Thecontrol system 1800 can continuously apply the opposite voltage polarityto the first electrical clutch circuit to continuously hold the firstclutch 6110 in its engaged position and maintain the operable engagementbetween the first drive ring 6120 and the drive screw 6130.Alternatively, the first clutch 6110 can be configured to become wedgedwithin the first drive ring 6120 when the first clutch 6110 is in itsengaged position and, in such instances, the control system 1800 may notneed to continuously apply a voltage polarity to the first electricalclutch circuit to hold the first clutch assembly 6100 in its engagedstate. In such instances, the control system 1800 can discontinueapplying the voltage polarity once the first clutch 6110 has beensufficiently wedged in the first drive ring 6120.

Notably, further to the above, the first clutch lock 6150 is alsoconfigured to lockout the jaw assembly drive when the first clutch 6110is in its disengaged position. More specifically, referring again toFIG. 28, the first clutch 6110 pushes the first clutch lock 6150 in thedrive screw 6130 into engagement with the outer housing 6230 of the endeffector 7000 when the first clutch 6110 is in its disengaged positionsuch that the drive screw 6130 does not rotate, or at leastsubstantially rotate, relative to the outer housing 6230. The outerhousing 6230 comprises a slot 6235 defined therein which is configuredto receive the first clutch lock 6150. When the first clutch 6110 ismoved into its engaged position, referring to FIG. 29, the first clutch6110 is no longer engaged with the first clutch lock 6150 and, as aresult, the first clutch lock 6150 is no longer biased into engagementwith the outer housing 6230 and the drive screw 6130 can rotate freelywith respect to the outer housing 6230. As a result of the above, thefirst clutch 6110 can do at least two things—operate the jaw drive whenthe first clutch 6110 is in its engaged position and lock out the jawdrive when the first clutch 6110 is in its disengaged position.

Moreover, further to the above, the threads of the threaded portions6160 and 7160 can be configured to prevent, or at least resist,backdriving of the jaw drive. In at least one instance, the thread pitchand/or angle of the threaded portions 6160 and 7160, for example, can beselected to prevent the backdriving, or unintentional opening, of thejaw assembly 7100. As a result of the above, the possibility of the jawassembly 7100 unintentionally opening or closing is prevented, or atleast reduced.

Referring primarily to FIG. 30, the second clutch system 6200 comprisesa second clutch 6210, an expandable second drive ring 6220, and a secondelectromagnetic actuator 6240. The second clutch 6210 comprises anannular ring and is slideably disposed on the drive shaft 2730. Thesecond clutch 6210 is comprised of a magnetic material and is movablebetween a disengaged, or unactuated, position (FIG. 30) and an engaged,or actuated, position (FIG. 31) by electromagnetic fields EF generatedby the second electromagnetic actuator 6240. In various instances, thesecond clutch 6210 is at least partially comprised of iron and/ornickel, for example. In at least one instance, the second clutch 6210comprises a permanent magnet. As illustrated in FIG. 22A, the driveshaft 2730 comprises one or more longitudinal key slots 6215 definedtherein which are configured to constrain the longitudinal movement ofthe second clutch 6210 relative to the drive shaft 2730. Morespecifically, the second clutch 6210 comprises one or more keysextending into the key slots 6215 such that the distal ends of the keyslots 6215 stop the distal movement of the second clutch 6210 and theproximal ends of the key slots 6215 stop the proximal movement of thesecond clutch 6210.

When the second clutch 6210 is in its disengaged position, referring toFIG. 30, the second clutch 6210 rotates with the drive shaft 2730 butdoes not transmit rotational motion to the second drive ring 6220. Ascan be seen in FIG. 30, the second clutch 6210 is separated from, or notin contact with, the second drive ring 6220. As a result, the rotationof the drive shaft 2730 and the second clutch 6210 is not transmitted tothe outer housing 6230 of the end effector 7000 when the second clutchassembly 6200 is in its disengaged state. When the second clutch 6210 isin its engaged position (FIG. 31), the second clutch 6210 is engagedwith the second drive ring 6220 such that the second drive ring 6220 isexpanded, or stretched, radially outwardly into contact with the outerhousing 6230. In at least one instance, the second drive ring 6220comprises an elastomeric band, for example. As can be seen in FIG. 31,the second drive ring 6220 is compressed against an annular innersidewall 7415 of the outer housing 6230. As a result, the rotation ofthe drive shaft 2730 and the second clutch 6210 is transmitted to theouter housing 6230 when the second clutch assembly 6200 is in itsengaged state. Depending on the direction in which the drive shaft 2730is rotated, the second clutch assembly 6200 can rotate the end effector7000 in a first direction or a second direction about the longitudinalaxis L when the second clutch assembly 6200 is in its engaged state.

As described above, the second electromagnetic actuator 6240 isconfigured to generate magnetic fields to move the second clutch 6210between its disengaged (FIG. 30) and engaged (FIG. 31) positions. Forinstance, the second electromagnetic actuator 6240 is configured to emita magnetic field EF_(L) which repulses, or drives, the second clutch6210 away from the second drive ring 6220 when the second clutchassembly 6200 is in its disengaged state. The second electromagneticactuator 6240 comprises one or more wound coils in a cavity defined inthe shaft frame 2530 which generate the magnetic field EF_(L) whencurrent flows in a first direction through a second electrical clutchcircuit including the wound coils. The control system 1800 is configuredto apply a first voltage polarity to the second electrical clutchcircuit to create the current flowing in the first direction. Thecontrol system 1800 can continuously apply the first voltage polarity tothe second electric clutch circuit to continuously hold the secondclutch 6120 in its disengaged position. While such an arrangement canprevent the second clutch 6210 from unintentionally engaging the seconddrive ring 6220, such an arrangement can also consume a lot of power.Alternatively, the control system 1800 can apply the first voltagepolarity to the second electrical clutch circuit for a sufficient periodof time to position the second clutch 6210 in its disengaged positionand then discontinue applying the first voltage polarity to the secondelectric clutch circuit, thereby resulting in a lower consumption ofpower. That being said, the second clutch assembly 6200 furthercomprises a second clutch lock 6250 mounted in the outer housing 6230which is configured to releasably hold the second clutch 6210 in itsdisengaged position. Similar to the above, the second clutch lock 6250can prevent, or at least reduce the possibility of, the second clutch6210 from becoming unintentionally engaged with the second drive ring6220. When the second clutch 6210 is in its disengaged position, asillustrated in FIG. 30, the second clutch lock 6250 interferes with thefree movement of the second clutch 6210 and holds the second clutch 6210in position via a friction and/or interference force therebetween. In atleast one instance, the second clutch lock 6250 comprises an elastomericplug, seat, or detent, comprised of rubber, for example. In certaininstances, the second clutch lock 6250 comprises a permanent magnetwhich holds the second clutch 6210 in its disengaged position by anelectromagnetic force. That said, the second electromagnetic actuator6240 can apply an electromagnetic pulling force to the second clutch6210 that overcomes these forces, as described in greater detail below.

Further to the above, referring to FIG. 31, the second electromagneticactuator 6240 is configured to emit a magnetic field EF_(D) which pulls,or drives, the second clutch 6210 toward the second drive ring 6220 whenthe second clutch assembly 6200 is in its engaged state. The coils ofthe second electromagnetic actuator 6240 generate the magnetic fieldEF_(D) when current flows in a second, or opposite, direction throughthe second electrical shaft circuit. The control system 1800 isconfigured to apply an opposite voltage polarity to the secondelectrical shaft circuit to create the current flowing in the oppositedirection. The control system 1800 can continuously apply the oppositevoltage polarity to the second electric shaft circuit to continuouslyhold the second clutch 6210 in its engaged position and maintain theoperable engagement between the second drive ring 6220 and the outerhousing 6230. Alternatively, the second clutch 6210 can be configured tobecome wedged within the second drive ring 6220 when the second clutch6210 is in its engaged position and, in such instances, the controlsystem 1800 may not need to continuously apply a voltage polarity to thesecond shaft electrical circuit to hold the second clutch assembly 6200in its engaged state. In such instances, the control system 1800 candiscontinue applying the voltage polarity once the second clutch 6210has been sufficiently wedged in the second drive ring 6220.

Notably, further to the above, the second clutch lock 6250 is alsoconfigured to lockout the rotation of the end effector 7000 when thesecond clutch 6210 is in its disengaged position. More specifically,referring again to FIG. 30, the second clutch 6210 pushes the secondclutch lock 6250 in the outer shaft 6230 into engagement with thearticulation link 2340 when the second clutch 6210 is in its disengagedposition such that the end effector 7000 does not rotate, or at leastsubstantially rotate, relative to the distal attachment portion 2400 ofthe shaft assembly 2000. As illustrated in FIG. 27, the second clutchlock 6250 is positioned or wedged within a slot, or channel, 2345defined in the articulation link 2340 when the second clutch 6210 is inits disengaged position. As a result of the above, the possibility ofthe end effector 7000 unintentionally rotating is prevented, or at leastreduced. Moreover, as a result of the above, the second clutch 6210 cando at least two things—operate the end effector rotation drive when thesecond clutch 6210 is in its engaged position and lock out the endeffector rotation drive when the second clutch 6210 is in its disengagedposition.

Referring primarily to FIGS. 22, 24, and 25, the shaft assembly 2000further comprises an articulation drive system configured to articulatethe distal attachment portion 2400 and the end effector 7000 about thearticulation joint 2300. The articulation drive system comprises anarticulation drive 6330 rotatably supported within the distal attachmentportion 2400. That said, the articulation drive 6330 is closely receivedwithin the distal attachment portion 2400 such that the articulationdrive 6330 does not translate, or at least substantially translate,relative to the distal attachment portion 2400. The articulation drivesystem of the shaft assembly 2000 further comprises a stationary gear2330 fixedly mounted to the articulation frame 2310. More specifically,the stationary gear 2330 is fixedly mounted to a pin connecting a tab2314 of the articulation frame 2310 and the articulation link 2340 suchthat the stationary gear 2330 does not rotate relative to thearticulation frame 2310. The stationary gear 2330 comprises a centralbody 2335 and an annular array of stationary teeth 2332 extending aroundthe perimeter of the central body 2335. The articulation drive 6330comprises an annular array of drive teeth 6332 which is meshinglyengaged with the stationary teeth 2332. When the articulation drive 6330is rotated, the articulation drive 6330 pushes against the stationarygear 2330 and articulates the distal attachment portion 2400 of theshaft assembly 2000 and the end effector 7000 about the articulationjoint 2300.

Referring primarily to FIG. 32, the third clutch system 6300 comprises athird clutch 6310, an expandable third drive ring 6320, and a thirdelectromagnetic actuator 6340. The third clutch 6310 comprises anannular ring and is slideably disposed on the drive shaft 2730. Thethird clutch 6310 is comprised of a magnetic material and is movablebetween a disengaged, or unactuated, position (FIG. 32) and an engaged,or actuated, position (FIG. 33) by electromagnetic fields EF generatedby the third electromagnetic actuator 6340. In various instances, thethird clutch 6310 is at least partially comprised of iron and/or nickel,for example. In at least one instance, the third clutch 6310 comprises apermanent magnet. As illustrated in FIG. 22A, the drive shaft 2730comprises one or more longitudinal key slots 6315 defined therein whichare configured to constrain the longitudinal movement of the thirdclutch 6310 relative to the drive shaft 2730. More specifically, thethird clutch 6310 comprises one or more keys extending into the keyslots 6315 such that the distal ends of the key slots 6315 stop thedistal movement of the third clutch 6310 and the proximal ends of thekey slots 6315 stop the proximal movement of the third clutch 6310.

When the third clutch 6310 is in its disengaged position, referring toFIG. 32, the third clutch 6310 rotates with the drive shaft 2730 butdoes not transmit rotational motion to the third drive ring 6320. As canbe seen in FIG. 32, the third clutch 6310 is separated from, or not incontact with, the third drive ring 6320. As a result, the rotation ofthe drive shaft 2730 and the third clutch 6310 is not transmitted to thearticulation drive 6330 when the third clutch assembly 6300 is in itsdisengaged state. When the third clutch 6310 is in its engaged position,referring to FIG. 33, the third clutch 6310 is engaged with the thirddrive ring 6320 such that the third drive ring 6320 is expanded, orstretched, radially outwardly into contact with the articulation drive6330. In at least one instance, the third drive ring 6320 comprises anelastomeric band, for example. As can be seen in FIG. 33, the thirddrive ring 6320 is compressed against an annular inner sidewall 6335 ofthe articulation drive 6330. As a result, the rotation of the driveshaft 2730 and the third clutch 6310 is transmitted to the articulationdrive 6330 when the third clutch assembly 6300 is in its engaged state.Depending on the direction in which the drive shaft 2730 is rotated, thethird clutch assembly 6300 can articulate the distal attachment portion2400 of the shaft assembly 2000 and the end effector 7000 in a first orsecond direction about the articulation joint 2300.

As described above, the third electromagnetic actuator 6340 isconfigured to generate magnetic fields to move the third clutch 6310between its disengaged (FIG. 32) and engaged (FIG. 33) positions. Forinstance, referring to FIG. 32, the third electromagnetic actuator 6340is configured to emit a magnetic field EF_(L) which repulses, or drives,the third clutch 6310 away from the third drive ring 6320 when the thirdclutch assembly 6300 is in its disengaged state. The thirdelectromagnetic actuator 6340 comprises one or more wound coils in acavity defined in the shaft frame 2530 which generate the magnetic fieldEF_(L) when current flows in a first direction through a thirdelectrical clutch circuit including the wound coils. The control system1800 is configured to apply a first voltage polarity to the thirdelectrical clutch circuit to create the current flowing in the firstdirection. The control system 1800 can continuously apply the firstvoltage polarity to the third electric clutch circuit to continuouslyhold the third clutch 6310 in its disengaged position. While such anarrangement can prevent the third clutch 6310 from unintentionallyengaging the third drive ring 6320, such an arrangement can also consumea lot of power. Alternatively, the control system 1800 can apply thefirst voltage polarity to the third electrical clutch circuit for asufficient period of time to position the third clutch 6310 in itsdisengaged position and then discontinue applying the first voltagepolarity to the third electric clutch circuit, thereby resulting in alower consumption of power.

Further to the above, the third electromagnetic actuator 6340 isconfigured to emit a magnetic field EF_(D) which pulls, or drives, thethird clutch 6310 toward the third drive ring 6320 when the third clutchassembly 6300 is in its engaged state. The coils of the thirdelectromagnetic actuator 6340 generate the magnetic field EF_(D) whencurrent flows in a second, or opposite, direction through the thirdelectrical clutch circuit. The control system 1800 is configured toapply an opposite voltage polarity to the third electrical shaft circuitto create the current flowing in the opposite direction. The controlsystem 1800 can continuously apply the opposite voltage polarity to thethird electric shaft circuit to continuously hold the third clutch 6310in its engaged position and maintain the operable engagement between thethird drive ring 6320 and the articulation drive 6330. Alternatively,the third clutch 6210 can be configured to become wedged within thethird drive ring 6320 when the third clutch 6310 is in its engagedposition and, in such instances, the control system 1800 may not need tocontinuously apply a voltage polarity to the third shaft electricalcircuit to hold the third clutch assembly 6300 in its engaged state. Insuch instances, the control system 1800 can discontinue applying thevoltage polarity once the third clutch 6310 has been sufficiently wedgedin the third drive ring 6320. In any event, the end effector 7000 isarticulatable in a first direction or a second direction, depending onthe direction in which the drive shaft 2730 is rotated, when the thirdclutch assembly 6300 is in its engaged state.

Further to the above, referring to FIGS. 22, 32, and 33, thearticulation drive system further comprises a lockout 6350 whichprevents, or at least inhibits, the articulation of the distalattachment portion 2400 of the shaft assembly 2000 and the end effector7000 about the articulation joint 2300 when the third clutch 6310 is inits disengaged position (FIG. 32). Referring primarily to FIG. 22, thearticulation link 2340 comprises a slot, or groove, 2350 defined thereinwherein the lockout 6350 is slideably positioned in the slot 2350 andextends at least partially under the stationary articulation gear 2330.The lockout 6350 comprises at attachment hook 6352 engaged with thethird clutch 6310. More specifically, the third clutch 6310 comprises anannular slot, or groove, 6312 defined therein and the attachment hook6352 is positioned in the annular slot 6312 such that the lockout 6350translates with the third clutch 6310. Notably, however, the lockout6350 does not rotate, or at least substantially rotate, with the thirdclutch 6310. Instead, the annular groove 6312 in the third clutch 6310permits the third clutch 6310 to rotate relative to the lockout 6350.The lockout 6350 further comprises a lockout hook 6354 slideablypositioned in a radially-extending lockout slot 2334 defined in thebottom of the stationary gear 2330. When the third clutch 6310 is in itsdisengaged position, as illustrated in FIG. 32, the lockout 6350 is in alocked position in which the lockout hook 6354 prevents the end effector7000 from rotating about the articulation joint 2300. When the thirdclutch 6310 is in its engaged position, as illustrated in FIG. 33, thelockout 6350 is in an unlocked position in which the lockout hook 6354is no longer positioned in the lockout slot 2334. Instead, the lockouthook 6354 is positioned in a clearance slot defined in the middle orbody 2335 of the stationary gear 2330. In such instances, the lockouthook 6354 can rotate within the clearance slot when the end effector7000 rotates about the articulation joint 2300.

Further to the above, the radially-extending lockout slot 2334 depictedin FIGS. 32 and 33 extends longitudinally, i.e., along an axis which isparallel to the longitudinal axis of the elongate shaft 2200. Once theend effector 7000 has been articulated, however, the lockout hook 6354is no longer aligned with the longitudinal lockout slot 2334. With thisin mind, the stationary gear 2330 comprises a plurality, or an array, ofradially-extending lockout slots 2334 defined in the bottom of thestationary gear 2330 such that, when the third clutch 6310 is deactuatedand the lockout 6350 is pulled distally after the end effector 7000 hasbeen articulated, the lockout hook 6354 can enter one of the lockoutslots 2334 and lock the end effector 7000 in its articulated position.Thus, as a result, the end effector 7000 can be locked in anunarticulated and an articulated position. In various instances, thelockout slots 2334 can define discrete articulated positions for the endeffector 7000. For instance, the lockout slots 2334 can be defined at 10degree intervals, for example, which can define discrete articulationorientations for the end effector 7000 at 10 degree intervals. In otherinstances, these orientations can be at 5 degree intervals, for example.In alternative embodiments, the lockout 6350 comprises a brake thatengages a circumferential shoulder defined in the stationary gear 2330when the third clutch 6310 is disengaged from the third drive ring 6320.In such an embodiment, the end effector 7000 can be locked in anysuitable orientation. In any event, the lockout 6350 prevents, or atleast reduces the possibility of, the end effector 7000 unintentionallyarticulating. As a result of the above, the third clutch 6310 can dothings—operate the articulation drive when it is in its engaged positionand lock out the articulation drive when it is in its disengagedposition.

Referring primarily to FIGS. 24 and 25, the shaft frame 2530 and thedrive shaft 2730 extend through the articulation joint 2300 into thedistal attachment portion 2400. When the end effector 7000 isarticulated, as illustrated in FIGS. 16 and 17, the shaft frame 2530 andthe drive shaft 2730 bend to accommodate the articulation of the endeffector 7000. Thus, the shaft frame 2530 and the drive shaft 2730 arecomprised of any suitable material which accommodates the articulationof the end effector 7000. Moreover, as discussed above, the shaft frame2530 houses the first, second, and third electromagnetic actuators 6140,6240, and 6340. In various instances, the first, second, and thirdelectromagnetic actuators 6140, 6240, and 6340 each comprise wound wirecoils, such as copper wire coils, for example, and the shaft frame 2530is comprised of an insulative material to prevent, or at least reducethe possibility of, short circuits between the first, second, and thirdelectromagnetic actuators 6140, 6240, and 6340. In various instances,the first, second, and third electrical clutch circuits extendingthrough the shaft frame 2530 are comprised of insulated electricalwires, for example. Further to the above, the first, second, and thirdelectrical clutch circuits place the electromagnetic actuators 6140,6240, and 6340 in communication with the control system 1800 in thedrive module 1100.

As described above, the clutches 6110, 6210, and/or 6310 can be held intheir disengaged positions so that they do not unintentionally move intotheir engaged positions. In various arrangements, the clutch system 6000comprises a first biasing member, such as a spring, for example,configured to bias the first clutch 6110 into its disengaged position, asecond biasing member, such as a spring, for example, configured to biasthe second clutch 6210 into its disengaged position, and/or a thirdbiasing member, such as a spring, for example, configured to bias thethird clutch 6110 into its disengaged position. In such arrangements,the biasing forces of the springs can be selectively overcome by theelectromagnetic forces generated by the electromagnetic actuators whenenergized by an electrical current. Further to the above, the clutches6110, 6210, and/or 6310 can be retained in their engaged positions bythe drive rings 6120, 6220, and/or 6320, respectively. Morespecifically, in at least one instance, the drive rings 6120, 6220,and/or 6320 are comprised of an elastic material which grips orfrictionally holds the clutches 6110, 6210, and/or 6310, respectively,in their engaged positions. In various alternative embodiments, theclutch system 6000 comprises a first biasing member, such as a spring,for example, configured to bias the first clutch 6110 into its engagedposition, a second biasing member, such as a spring, for example,configured to bias the second clutch 6210 into its engaged position,and/or a third biasing member, such as a spring, for example, configuredto bias the third clutch 6110 into its engaged position. In sucharrangements, the biasing forces of the springs can be overcome by theelectromagnetic forces applied by the electromagnetic actuators 6140,6240, and/or 6340, respectively, as needed to selectively hold theclutches 6110, 6210, and 6310 in their disengaged positions. In any oneoperational mode of the surgical system, the control assembly 1800 canenergize one of the electromagnetic actuators to engage one of theclutches while energizing the other two electromagnetic actuators todisengage the other two clutches.

Although the clutch system 6000 comprises three clutches to controlthree drive systems of the surgical system, a clutch system can compriseany suitable number of clutches to control any suitable number ofsystems. Moreover, although the clutches of the clutch system 6000 slideproximally and distally between their engaged and disengaged positions,the clutches of a clutch system can move in any suitable manner. Inaddition, although the clutches of the clutch system 6000 are engagedone at a time to control one drive motion at a time, various instancesare envisioned in which more than one clutch can be engaged to controlmore than one drive motion at a time.

In view of the above, the reader should appreciate that the controlsystem 1800 is configured to, one, operate the motor system 1600 torotate the drive shaft system 2700 in an appropriate direction and, two,operate the clutch system 6000 to transfer the rotation of the driveshaft system 2700 to the appropriate function of the end effector 7000.Moreover, as discussed above, the control system 1800 is responsive toinputs from the clamping trigger system 2600 of the shaft assembly 2000and the input system 1400 of the handle 1000. When the clamping triggersystem 2600 is actuated, as discussed above, the control system 1800activates the first clutch assembly 6100 and deactivates the secondclutch assembly 6200 and the third clutch assembly 6300. In suchinstances, the control system 1800 also supplies power to the motorsystem 1600 to rotate the drive shaft system 2700 in a first directionto clamp the jaw assembly 7100 of the end effector 7000. When thecontrol system 1800 detects that the jaw assembly 7100 is in its clampedconfiguration, the control system 1800 stops the motor assembly 1600 anddeactivates the first clutch assembly 6100. When the control system 1800detects that the clamping trigger system 2600 has been moved to, or isbeing moved to, its unactuated position, the control system 1800activates, or maintains the activation of, the first clutch assembly6100 and deactivates, or maintains the deactivation of, the secondclutch assembly 6200 and the third clutch assembly 6300. In suchinstances, the control system 1800 also supplies power to the motorsystem 1600 to rotate the drive shaft system 2700 in a second directionto open the jaw assembly 7100 of the end effector 7000.

When the rotation actuator 1420 is actuated in a first direction,further to the above, the control system 1800 activates the secondclutch assembly 6200 and deactivates the first clutch assembly 6100 andthe third clutch assembly 6300. In such instances, the control system1800 also supplies power to the motor system 1600 to rotate the driveshaft system 2700 in a first direction to rotate the end effector 7000in a first direction. When the control system 1800 detects that therotation actuator 1420 has been actuated in a second direction, thecontrol system 1800 activates, or maintains the activation of, thesecond clutch assembly 6200 and deactivates, or maintains thedeactivation of, the first clutch assembly 6100 and the third clutchassembly 6300. In such instances, the control system 1800 also suppliespower to the motor system 1600 to rotate the drive shaft system 2700 ina second direction to rotate the drive shaft system 2700 in a seconddirection to rotate the end effector 7000 in a second direction. Whenthe control system 1800 detects that the rotation actuator 1420 is notactuated, the control system 1800 deactivates the second clutch assembly6200.

When the first articulation actuator 1432 is depressed, further to theabove, the control system 1800 activates the third clutch assembly 6300and deactivates the first clutch assembly 6100 and the second clutchassembly 6200. In such instances, the control system 1800 also suppliespower to the motor system 1600 to rotate the drive shaft system 2700 ina first direction to articulate the end effector 7000 in a firstdirection. When the control system 1800 detects that the secondarticulation actuator 1434 is depressed, the control system 1800activates, or maintains the activation of, the third clutch assembly6200 and deactivates, or maintains the deactivation of, the first clutchassembly 6100 and the second clutch assembly 6200. In such instances,the control system 1800 also supplies power to the motor system 1600 torotate the drive shaft system 2700 in a second direction to articulatethe end effector 7000 in a second direction. When the control system1800 detects that neither the first articulation actuator 1432 nor thesecond articulation actuator 1434 are actuated, the control system 1800deactivates the third clutch assembly 6200.

Further to the above, the control system 1800 is configured to changethe operating mode of the stapling system based on the inputs itreceives from the clamping trigger system 2600 of the shaft assembly2000 and the input system 1400 of the handle 1000. The control system1800 is configured to shift the clutch system 6000 before rotating theshaft drive system 2700 to perform the corresponding end effectorfunction. Moreover, the control system 1800 is configured to stop therotation of the shaft drive system 2700 before shifting the clutchsystem 6000. Such an arrangement can prevent the sudden movements in theend effector 7000. Alternatively, the control system 1800 can shift theclutch system 600 while the shaft drive system 2700 is rotating. Such anarrangement can allow the control system 1800 to shift quickly betweenoperating modes.

As discussed above, referring to FIG. 34, the distal attachment portion2400 of the shaft assembly 2000 comprises an end effector lock 6400configured to prevent the end effector 7000 from being unintentionallydecoupled from the shaft assembly 2000. The end effector lock 6400comprises a lock end 6410 selectively engageable with the annular arrayof lock notches 7410 defined on the proximal attachment portion 7400 ofthe end effector 7000, a proximal end 6420, and a pivot 6430 rotatablyconnecting the end effector lock 6400 to the articulation link 2320.When the third clutch 6310 of the third clutch assembly 6300 is in itsdisengaged position, as illustrated in FIG. 34, the third clutch 6310 iscontact with the proximal end 6420 of the end effector lock 6400 suchthat the lock end 6410 of the end effector lock 6400 is engaged with thearray of lock notches 7410. In such instances, the end effector 7000 canrotate relative to the end effector lock 6400 but cannot translaterelative to the distal attachment portion 2400. When the third clutch6310 is moved into its engaged position, as illustrated in FIG. 35, thethird clutch 6310 is no longer engaged with the proximal end 6420 of theend effector lock 6400. In such instances, the end effector lock 6400 isfree to pivot upwardly and permit the end effector 7000 to be detachedfrom the shaft assembly 2000.

The above being said, referring again to FIG. 34, it is possible thatthe second clutch 6210 of the second clutch assembly 6200 is in itsdisengaged position when the clinician detaches, or attempts to detach,the end effector 7000 from the shaft assembly 2000. As discussed above,the second clutch 6210 is engaged with the second clutch lock 6250 whenthe second clutch 6210 is in its disengaged position and, in suchinstances, the second clutch lock 6250 is pushed into engagement withthe articulation link 2340. More specifically, the second clutch lock6250 is positioned in the channel 2345 defined in the articulation 2340when the second clutch 6210 is engaged with the second clutch lock 6250which may prevent, or at least impede, the end effector 7000 from beingdetached from the shaft assembly 2000. To facilitate the release of theend effector 7000 from the shaft assembly 2000, the control system 1800can move the second clutch 6210 into its engaged position in addition tomoving the third clutch 6310 into its engaged position. In suchinstances, the end effector 7000 can clear both the end effector lock6400 and the second clutch lock 6250 when the end effector 7000 isremoved.

In at least one instance, further to the above, the drive module 1100comprises an input switch and/or sensor in communication with thecontrol system 1800 via the input system 1400, and/or the control system1800 directly, which, when actuated, causes the control system 1800 tounlock the end effector 7000. In various instances, the drive module1100 comprises an input screen 1440 in communication with the board 1410of the input system 1400 which is configured to receive an unlock inputfrom the clinician. In response to the unlock input, the control system1800 can stop the motor system 1600, if it is running, and unlock theend effector 7000 as described above. The input screen 1440 is alsoconfigured to receive a lock input from the clinician in which the inputsystem 1800 moves the second clutch assembly 6200 and/or the thirdclutch assembly 6300 into their unactuated states to lock the endeffector 7000 to the shaft assembly 2000.

FIG. 37 depicts a shaft assembly 2000′ in accordance with at least onealternative embodiment. The shaft assembly 2000′ is similar to the shaftassembly 2000 in many respects, most of which will not be repeatedherein for the sake of brevity. Similar to the shaft assembly 2000, theshaft assembly 2000′ comprises a shaft frame, i.e., shaft frame 2530′.The shaft frame 2530′ comprises a longitudinal passage 2535′ and, inaddition, a plurality of clutch position sensors, i.e., a first sensor6180′, a second sensor 6280′, and a third sensor 6380′ positioned in theshaft frame 2530′. The first sensor 6180′ is in signal communicationwith the control system 1800 as part of a first sensing circuit. Thefirst sensing circuit comprises signal wires extending through thelongitudinal passage 2535′; however, the first sensing circuit cancomprise a wireless signal transmitter and receiver to place the firstsensor 6180′ in signal communication with the control system 1800. Thefirst sensor 6180′ is positioned and arranged to detect the position ofthe first clutch 6110 of the first clutch assembly 6100. Based on datareceived from the first sensor 6180′, the control system 1800 candetermine whether the first clutch 6110 is in its engaged position, itsdisengaged position, or somewhere in-between. With this information, thecontrol system 1800 can assess whether or not the first clutch 6110 isin the correct position given the operating state of the surgicalinstrument. For instance, if the surgical instrument is in its jawclamping/opening operating state, the control system 1800 can verifywhether the first clutch 6110 is properly positioned in its engagedposition. In such instances, further to the below, the control system1800 can also verify that the second clutch 6210 is in its disengagedposition via the second sensor 6280′ and that the third clutch 6310 isin its disengaged position via the third sensor 6380′. Correspondingly,the control system 1800 can verify whether the first clutch 6110 isproperly positioned in its disengaged position if the surgicalinstrument is not in its jaw clamping/opening state. To the extent thatthe first clutch 6110 is not in its proper position, the control system1800 can actuate the first electromagnetic actuator 6140 in an attemptto properly position the first clutch 6110. Likewise, the control system1800 can actuate the electromagnetic actuators 6240 and/or 6340 toproperly position the clutches 6210 and/or 6310, if necessary.

The second sensor 6280′ is in signal communication with the controlsystem 1800 as part of a second sensing circuit. The second sensingcircuit comprises signal wires extending through the longitudinalpassage 2535′; however, the second sensing circuit can comprise awireless signal transmitter and receiver to place the second sensor6280′ in signal communication with the control system 1800. The secondsensor 6280′ is positioned and arranged to detect the position of thesecond clutch 6210 of the first clutch assembly 6200. Based on datareceived from the second sensor 6280′, the control system 1800 candetermine whether the second clutch 6210 is in its engaged position, itsdisengaged position, or somewhere in-between. With this information, thecontrol system 1800 can assess whether or not the second clutch 6210 isin the correct position given the operating state of the surgicalinstrument. For instance, if the surgical instrument is in its endeffector rotation operating state, the control system 1800 can verifywhether the second clutch 6210 is properly positioned in its engagedposition. In such instances, the control system 1800 can also verifythat the first clutch 6110 is in its disengaged position via the firstsensor 6180′ and, further to the below, the control system 1800 can alsoverify that the third clutch 6310 is in its disengaged position via thethird sensor 6380′. Correspondingly, the control system 1800 can verifywhether the second clutch 6110 is properly positioned in its disengagedposition if the surgical instrument is not in its end effector rotationstate. To the extent that the second clutch 6210 is not in its properposition, the control system 1800 can actuate the second electromagneticactuator 6240 in an attempt to properly position the second clutch 6210.Likewise, the control system 1800 can actuate the electromagneticactuators 6140 and/or 6340 to properly position the clutches 6110 and/or6310, if necessary.

The third sensor 6380′ is in signal communication with the controlsystem 1800 as part of a third sensing circuit. The third sensingcircuit comprises signal wires extending through the longitudinalpassage 2535′; however, the third sensing circuit can comprise awireless signal transmitter and receiver to place the third sensor 6380′in signal communication with the control system 1800. The third sensor6380′ is positioned and arranged to detect the position of the thirdclutch 6310 of the third clutch assembly 6300. Based on data receivedfrom the third sensor 6380′, the control system 1800 can determinewhether the third clutch 6310 is in its engaged position, its disengagedposition, or somewhere in-between. With this information, the controlsystem 1800 can assess whether or not the third clutch 6310 is in thecorrect position given the operating state of the surgical instrument.For instance, if the surgical instrument is in its end effectorarticulation operating state, the control system 1800 can verify whetherthe third clutch 6310 is properly positioned in its engaged position. Insuch instances, the control system 1800 can also verify that the firstclutch 6110 is in its disengaged position via the first sensor 6180′ andthat the second clutch 6210 is in its disengaged position via the secondsensor 6280′. Correspondingly, the control system 1800 can verifywhether the third clutch 6310 is properly positioned in its disengagedposition if the surgical instrument is not in its end effectorarticulation state. To the extent that the third clutch 6310 is not inits proper position, the control system 1800 can actuate the thirdelectromagnetic actuator 6340 in an attempt to properly position thethird clutch 6310. Likewise, the control system 1800 can actuate theelectromagnetic actuators 6140 and/or 6240 to properly position theclutches 6110 and/or 6210, if necessary.

Further to the above, the clutch position sensors, i.e., the firstsensor 6180′, the second sensor 6280′, and the third sensor 6380′ cancomprise any suitable type of sensor. In various instances, the firstsensor 6180′, the second sensor 6280′, and the third sensor 6380′ eachcomprise a proximity sensor. In such an arrangement, the sensors 6180′,6280′, and 6380′ are configured to detect whether or not the clutches6110, 6210, and 6310, respectively, are in their engaged positions. Invarious instances, the first sensor 6180′, the second sensor 6280′, andthe third sensor 6380′ each comprise a Hall Effect sensor, for example.In such an arrangement, the sensors 6180′, 6280′, and 6380′ can not onlydetect whether or not the clutches 6110, 6210, and 6310, respectively,are in their engaged positions but the sensors 6180′, 6280′, and 6380′can also detect how close the clutches 6110, 6210, and 6310 are withrespect to their engaged or disengaged positions.

FIG. 38 depicts the shaft assembly 2000′ and an end effector 7000″ inaccordance with at least one alternative embodiment. The end effector7000″ is similar to the end effector 7000 in many respects, most ofwhich will not be repeated herein for the sake of brevity. Similar tothe end effector 7000, the shaft assembly 7000″ comprises a jaw assembly7100 and a jaw assembly drive configured to move the jaw assembly 7100between its open and closed configurations. The jaw assembly drivecomprises drive links 7140, a drive nut 7150″, and a drive screw 6130″.The drive nut 7150″ comprises a sensor 7190″ positioned therein which isconfigured to detect the position of a magnetic element 6190″ positionedin the drive screw 6130″. The magnetic element 6190″ is positioned in anelongate aperture 6134″ defined in the drive screw 6130″ and cancomprise a permanent magnet and/or can be comprised of iron, nickel,and/or any suitable metal, for example. In various instances, the sensor7190″ comprises a proximity sensor, for example, which is in signalcommunication with the control system 1800. In certain instances, thesensor 7190″ comprises a Hall Effect sensor, for example, in signalcommunication with the control system 1800. In certain instances, thesensor 7190″ comprises an optical sensor, for example, and thedetectable element 6190″ comprises an optically detectable element, suchas a reflective element, for example. In either event, the sensor 7190″is configured to communicate wirelessly with the control system 1800 viaa wireless signal transmitter and receiver and/or via a wired connectionextending through the shaft frame passage 2532′, for example.

The sensor 7190″, further to the above, is configured to detect when themagnetic element 6190″ is adjacent to the sensor 7190″ such that thecontrol system 1800 can use this data to determine that the jaw assembly7100 has reached the end of its clamping stroke. At such point, thecontrol system 1800 can stop the motor assembly 1600. The sensor 7190″and the control system 1800 are also configured to determine thedistance between where the drive screw 6130″ is currently positioned andwhere the drive screw 6130″ should be positioned at the end of itsclosure stroke in order to calculate the amount of closure stroke of thedrive screw 6130″ that is still needed to close the jaw assembly 7100.Moreover, such information can be used by the control system 1800 toassess the current configuration of the jaw assembly 7100, i.e., whetherthe jaw assembly 7100 is in its open configuration, its closedconfiguration, or a partially closed configuration. The sensor systemcould be used to determine when the jaw assembly 7100 has reached itsfully open position and stop the motor assembly 1600 at that point. Invarious instances, the control system 1800 could use this sensor systemto confirm that the first clutch assembly 6100 is in its actuated stateby confirming that the jaw assembly 7100 is moving while the motorassembly 1600 is turning. Similarly, the control system 1800 could usethis sensor system to confirm that the first clutch assembly 6100 is inits unactuated state by confirming that the jaw assembly 7100 is notmoving while the motor assembly 1600 is turning.

FIG. 39 depicts a shaft assembly 2000′″ and an end effector 7000′″ inaccordance with at least one alternative embodiment. The shaft assembly2000′″ is similar to the shaft assemblies 2000 and 2000′ in manyrespects, most of which will not be repeated herein for the sake ofbrevity. The end effector 7000′″ is similar to the end effectors 7000and 7000″ in many respects, most of which will not be repeated hereinfor the sake of brevity. Similar to the end effector 7000, the endeffector 7000′″ comprises a jaw assembly 7100 and a jaw assembly driveconfigured to move the jaw assembly 7100 between its open and closedconfigurations and, in addition, an end effector rotation drive thatrotates the end effector 7000′″ relative to the distal attachmentportion 2400 of the shaft assembly 2000′. The end effector rotationdrive comprises an outer housing 6230′″ that is rotated relative to ashaft frame 2530′″ of the end effector 7000′″ by the second clutchassembly 6200. The shaft frame 2530′″ comprises a sensor 6290′″positioned therein which is configured to detect the position of amagnetic element 6190′″ positioned in and/or on the outer housing6230′″. The magnetic element 6190′″ can comprise a permanent magnetand/or can be comprised of iron, nickel, and/or any suitable metal, forexample. In various instances, the sensor 6290′″ comprises a proximitysensor, for example, in signal communication with the control system1800. In certain instances, the sensor 6290′″ comprises a Hall Effectsensor, for example, in signal communication with the control system1800. In either event, the sensor 6290′″ is configured to communicatewirelessly with the control system 1800 via a wireless signaltransmitter and receiver and/or via a wired connection extending throughthe shaft frame passage 2532′, for example. In various instances, thecontrol system 1800 can use the sensor 6290′″ to confirm whether themagnetic element 6190′″ is rotating and, thus, confirm that the secondclutch assembly 6200 is in its actuated state. Similarly, the controlsystem 1800 can use the sensor 6290′″ to confirm whether the magneticelement 6190′″ is not rotating and, thus, confirm that the second clutchassembly 6200 is in its unactuated state. The control system 1800 canalso use the sensor 6290′″ to confirm that the second clutch assembly6200 is in its unactuated state by confirming that the second clutch6210 is positioned adjacent the sensor 6290′″.

FIG. 40 depicts a shaft assembly 2000″″ in accordance with at least onealternative embodiment. The shaft assembly 2000″″ is similar to theshaft assemblies 2000, 2000′, and 2000′″ in many respects, most of whichwill not be repeated herein for the sake of brevity. Similar to theshaft assembly 2000, the shaft assembly 2000″″ comprises, among otherthings, an elongate shaft 2200, an articulation joint 2300, and a distalattachment portion 2400 configured to receive an end effector, such asend effector 7000′, for example. Similar to the shaft assembly 2000, theshaft assembly 2000″″ comprises an articulation drive, i.e.,articulation drive 6330″″ configured to rotate the distal attachmentportion 2400 and the end effector 7000′ about the articulation joint2300. Similar to the above, a shaft frame 2530″″ comprises a sensorpositioned therein configured to detect the position, and/or rotation,of a magnetic element 6390″″ positioned in and/or on the articulationdrive 6330″″. The magnetic element 6390″″ can comprise a permanentmagnet and/or can be comprised of iron, nickel, and/or any suitablemetal, for example. In various instances, the sensor comprises aproximity sensor, for example, in signal communication with the controlsystem 1800. In certain instances, the sensor comprises a Hall Effectsensor, for example, in signal communication with the control system1800. In either event, the sensor is configured to communicatewirelessly with the control system 1800 via a wireless signaltransmitter and receiver and/or via a wired connection extending throughthe shaft frame passage 2532′, for example. In various instances, thecontrol system 1800 can use the sensor to confirm whether the magneticelement 6390″″ is rotating and, thus, confirm that the third clutchassembly 6300 is in its actuated state. Similarly, the control system1800 can use the sensor to confirm whether the magnetic element 6390″″is not rotating and, thus, confirm that the third clutch assembly 6300is in its unactuated state. In certain instances, the control system1800 can use the sensor to confirm that the third clutch assembly 6300is in its unactuated state by confirming that the third clutch 6310 ispositioned adjacent the sensor.

Referring to FIG. 40 once again, the shaft assembly 2000″″ comprises anend effector lock 6400′ configured to releasably lock the end effector7000′, for example, to the shaft assembly 2000″″. The end effector lock6400′ is similar to the end effector lock 6400 in many respects, most ofwhich will not be discussed herein for the sake of brevity. Notably,though, a proximal end 6420′ of the lock 6400′ comprises a tooth 6422′configured to engage the annular slot 6312 of the third clutch 6310 andreleasably hold the third clutch 6310 in its disengaged position. Thatsaid, the actuation of the third electromagnetic assembly 6340 candisengage the third clutch 6310 from the end effector lock 6400′.Moreover, in such instances, the proximal movement of the third clutch6310 into its engaged position rotates the end effector lock 6400′ intoa locked position and into engagement with the lock notches 7410 to lockthe end effector 7000′ to the shaft assembly 2000″″. Correspondingly,the distal movement of the third clutch 6310 into its disengagedposition unlocks the end effector 7000′ and allows the end effector7000′ to be disassembled from the shaft assembly 2000″″.

Further to the above, an instrument system including a handle and ashaft assembly attached thereto can be configured to perform adiagnostic check to assess the state of the clutch assemblies 6100,6200, and 6300. In at least one instance, the control system 1800sequentially actuates the electromagnetic actuators 6140, 6240, and/or6340—in any suitable order—to verify the positions of the clutches 6110,6210, and/or 6310, respectively, and/or verify that the clutches areresponsive to the electromagnetic actuators and, thus, not stuck. Thecontrol system 1800 can use sensors, including any of the sensorsdisclosed herein, to verify the movement of the clutches 6110, 6120, and6130 in response to the electromagnetic fields created by theelectromagnetic actuators 6140, 6240, and/or 6340. In addition, thediagnostic check can also include verifying the motions of the drivesystems. In at least one instance, the control system 1800 sequentiallyactuates the electromagnetic actuators 6140, 6240, and/or 6340—in anysuitable order—to verify that the jaw drive opens and/or closes the jawassembly 7100, the rotation drive rotates the end effector 7000, and/orthe articulation drive articulates the end effector 7000, for example.The control system 1800 can use sensors to verify the motions of the jawassembly 7100 and end effector 7000.

The control system 1800 can perform the diagnostic test at any suitabletime, such as when a shaft assembly is attached to the handle and/orwhen the handle is powered on, for example. If the control system 1800determines that the instrument system passed the diagnostic test, thecontrol system 1800 can permit the ordinary operation of the instrumentsystem. In at least one instance, the handle can comprise an indicator,such as a green LED, for example, which indicates that the diagnosticcheck has been passed. If the control system 1800 determines that theinstrument system failed the diagnostic test, the control system 1800can prevent and/or modify the operation of the instrument system. In atleast one instance, the control system 1800 can limit the functionalityof the instrument system to only the functions necessary to remove theinstrument system from the patient, such as straightening the endeffector 7000 and/or opening and closing the jaw assembly 7100, forexample. In at least one respect, the control system 1800 enters into alimp mode. The limp mode of the control system 1800 can reduce a currentrotational speed of the motor 1610 by any percentage selected from arange of about 75% to about 25%, for example. In one example, the limpmode reduces a current rotational speed of the motor 1610 by 50%. In oneexample, the limp mode reduces the current rotational speed of the motor1610 by 75%. The limp mode may cause a current torque of the motor 1610to be reduced by any percentage selected from a range of about 75% toabout 25%, for example. In one example, the limp mode reduces a currenttorque of the motor 1610 by 50%. The handle can comprise an indicator,such as a red LED, for example, which indicates that the instrumentsystem failed the diagnostic check and/or that the instrument system hasentered into a limp mode. The above being said, any suitable feedbackcan be used to warn the clinician that the instrument system is notoperating properly such as, for example, an audible warning and/or atactile or vibratory warning, for example.

FIGS. 41-43 depict a clutch system 6000′ in accordance with at least onealternative embodiment. The clutch system 6000′ is similar to the clutchsystem 6000 in many respects, most of which will not be repeated hereinfor the sake of brevity. Similar to the clutch system 6000, the clutchsystem 6000′ comprises a clutch assembly 6100′ which is actuatable toselectively couple a rotatable drive input 6030′ with a rotatable driveoutput 6130′. The clutch assembly 6100′ comprises clutch plates 6110′and drive rings 6120′. The clutch plates 6110′ are comprised of amagnetic material, such as iron and/or nickel, for example, and cancomprise a permanent magnet. As described in greater detail below, theclutch plates 6110′ are movable between unactuated positions (FIG. 42)and actuated positions (FIG. 43) within the drive output 6130′. Theclutch plates 6110′ are slideably positioned in apertures defined in thedrive output 6130′ such that the clutch plates 6110′ rotate with thedrive output 6130′ regardless of whether the clutch plates 6110′ are intheir unactuated or actuated positions.

When the clutch plates 6110′ are in their unactuated positions, asillustrated in FIG. 42, the rotation of the drive input 6030′ is nottransferred to the drive output 6130′. More specifically, when the driveinput 6030′ is rotated, in such instances, the drive input 6030′ slidespast and rotates relative to the drive rings 6120′ and, as a result, thedrive rings 6120′ do not drive the clutch plates 6110′ and the driveoutput 6130′. When the clutch plates 6110′ are in their actuatedpositions, as illustrated in FIG. 43, the clutch plates 6110′resiliently compress the drive rings 6120′ against the drive input6030′. The drive rings 6120′ are comprised of any suitable compressiblematerial, such as rubber, for example. In any event, in such instances,the rotation of the drive input 6030′ is transferred to the drive output6130′ via the drive rings 6120′ and the clutch plates 6110′. The clutchsystem 6000′ comprises a clutch actuator 6140′ configured to move theclutch plates 6110′ into their actuated positions. The clutch actuator6140′ is comprised of a magnetic material such as iron and/or nickel,for example, and can comprise a permanent magnet. The clutch actuator6140′ is slideably positioned in a longitudinal shaft frame 6050′extending through the drive input 6030′ and can be moved between anunactuated position (FIG. 42) and an actuated position (FIG. 43) by aclutch shaft 6060′. In at least one instance, the clutch shaft 6060′comprises a polymer cable, for example. When the clutch actuator 6140′is in its actuated position, as illustrated in FIG. 43, the clutchactuator 6140′ pulls the clutch plates 6110′ inwardly to compress thedrive rings 6120′, as discussed above. When the clutch actuator 6140′ ismoved into its unactuated position, as illustrated in FIG. 42, the driverings 6120′ resiliently expand and push the clutch plates 6110′ awayfrom the drive input 6030′. In various alternative embodiments, theclutch actuator 6140′ can comprise an electromagnet. In such anarrangement, the clutch actuator 6140′ can be actuated by an electricalcircuit extending through a longitudinal aperture defined in the clutchshaft 6060′, for example. In various instances, the clutch system 6000′further comprises electrical wires 6040′, for example, extending throughthe longitudinal aperture.

FIG. 44 depicts an end effector 7000 a including a jaw assembly 7100 a,a jaw assembly drive, and a clutch system 6000 a in accordance with atleast one alternative embodiment. The jaw assembly 7100 a comprises afirst jaw 7110 a and a second jaw 7120 a which are selectively rotatableabout a pivot 7130 a. The jaw assembly drive comprises a translatableactuator rod 7160 a and drive links 7140 a which are pivotably coupledto the actuator rod 7160 a about a pivot 7150 a. The drive links 7140 aare also pivotably coupled to the jaws 7110 a and 7120 a such that thejaws 7110 a and 7120 a are rotated closed when the actuator rod 7160 ais pulled proximally and rotated open when the actuator rod 7160 a ispushed distally. The clutch system 6000 a is similar to the clutchsystems 6000 and 6000′ in many respects, most of which will not berepeated herein for the sake of brevity. The clutch system 6000 acomprises a first clutch assembly 6100 a and a second clutch assembly6200 a which are configured to selectively transmit the rotation of adrive input 6030 a to rotate the jaw assembly 7100 a about alongitudinal axis and articulate the jaw assembly 7100 a about anarticulation joint 7300 a, respectively, as described in greater detailbelow.

The first clutch assembly 6100 a comprises clutch plates 6110 a anddrive rings 6120 a and work in a manner similar to the clutch plates6110′ and drive rings 6120′ discussed above. When the clutch plates 6110a are actuated by an electromagnetic actuator 6140 a, the rotation ofthe drive input 6030 a is transferred to an outer shaft housing 7200 a.More specifically, the outer shaft housing 7200 a comprises a proximalouter housing 7210 a and a distal outer housing 7220 a which isrotatably supported by the proximal outer housing 7210 a and is rotatedrelative to the proximal outer housing 7210 a by the drive input 6030 awhen the clutch plates 6110 a are in their actuated position. Therotation of the distal outer housing 7220 a rotates the jaw assembly7100 a about the longitudinal axis owing to fact that the pivot 7130 aof the jaw assembly 7100 a is mounted to the distal outer housing 7220a. As a result, the outer shaft housing 7200 a rotates the jaw assembly7100 a in a first direction when the outer shaft housing 7200 a isrotated in a first direction by the drive input 6030 a. Similarly, theouter shaft housing 7200 a rotates the jaw assembly 7100 a in a seconddirection when the outer shaft housing 7200 a is rotated in a seconddirection by the drive input 6030 a. When the electromagnetic actuator6140 a is de-energized, the drive rings 6120 a expand and the clutchplates 6110 a are moved into their unactuated positions, therebydecoupling the end effector rotation drive from the drive input 6030 a.

The second clutch assembly 6200 a comprises clutch plates 6210 a anddrive rings 6220 a and work in a manner similar to the clutch plates6110′ and drive rings 6120′ discussed above. When the clutch plates 6210a are actuated by an electromagnetic actuator 6240 a, the rotation ofthe drive input 6030 a is transferred to an articulation drive 6230 a.The articulation drive 6230 a is rotatably supported within an outershaft housing 7410 a of an end effector attachment portion 7400 a and isrotatably supported by a shaft frame 6050 a extending through the outershaft housing 7410 a. The articulation drive 6230 a comprises a gearface defined thereon which is operably intermeshed with a stationarygear face 7230 a defined on the proximal outer housing 7210 a of theouter shaft housing 7200 a. As a result, the articulation drive 6230 aarticulates the outer shaft housing 7200 a and the jaw assembly 7100 ain a first direction when the articulation drive 6230 a is rotated in afirst direction by the drive input 6030 a. Similarly, the articulationdrive 6230 a articulates the outer shaft housing 7200 a and the jawassembly 7100 a in a second direction when the articulation drive 6230 ais rotated in a second direction by the drive input 6030 a. When theelectromagnetic actuator 6240 a is de-energized, the drive rings 6220 aexpand and the clutch plates 6210 a are moved into their unactuatedpositions, thereby decoupling the end effector articulation drive fromthe drive input 6030 a.

Further to the above, the shaft assembly 4000 is illustrated in FIGS.45-49. The shaft assembly 4000 is similar to the shaft assemblies 2000,2000′, 2000′″, and 2000″″ in many respects, most of which will not berepeated herein for the sake of brevity. The shaft assembly 4000comprises a proximal portion 4100, an elongate shaft 4200, a distalattachment portion 2400, and an articulate joint 2300 which rotatablyconnects the distal attachment portion 2040 to the elongate shaft 4200.The proximal portion 4100, similar to the proximal portion 2100, isoperably attachable to the drive module 1100 of the handle 1000. Theproximal portion 4100 comprises a housing 4110 including an attachmentinterface 4130 configured to mount the shaft assembly 4000 to theattachment interface 1130 of the handle 1000. The shaft assembly 4000further comprises a frame 4500 including a shaft 4510 configured to becoupled to the shaft 1510 of the handle frame 1500 when the shaftassembly 4000 is attached to the handle 1000. The shaft assembly 4000also comprises a drive system 4700 including a rotatable drive shaft4710 configured to be operably coupled to the drive shaft 1710 of thehandle drive system 1700 when the shaft assembly 4000 is attached to thehandle 1000. The distal attachment portion 2400 is configured to receivean end effector, such as end effector 8000, for example. The endeffector 8000 is similar to the end effector 7000 in many respects, mostof which will not be repeated herein for the sake of brevity. That said,the end effector 8000 comprises a jaw assembly 8100 configured to, amongother things, grasp tissue.

As discussed above, referring primarily to FIGS. 47-49, the frame 4500of the shaft assembly 4000 comprises a frame shaft 4510. The frame shaft4510 comprises a notch, or cut-out, 4530 defined therein. As discussedin greater detail below, the cut-out 4530 is configured to provideclearance for a jaw closure actuation system 4600. The frame 4500further comprises a distal portion 4550 and a bridge 4540 connecting thedistal portion 4550 to the frame shaft 4510. The frame 4500 furthercomprises a longitudinal portion 4560 extending through the elongateshaft 4200 to the distal attachment portion 2400. Similar to the above,the frame shaft 4510 comprises one or more electrical traces definedthereon and/or therein. The electrical traces extend through thelongitudinal portion 4560, the distal portion 4550, the bridge 4540,and/or any suitable portion of the frame shaft 4510 to the electricalcontacts 2520. Referring primarily to FIG. 48, the distal portion 4550and longitudinal portion 4560 comprise a longitudinal aperture definedtherein which is configured to receive a rod 4660 of the jaw closureactuation system 4600, as described in greater detail below.

As also discussed above, referring primarily to FIGS. 48 and 49, thedrive system 4700 of the shaft assembly 4000 comprises a drive shaft4710. The drive shaft 4710 is rotatably supported within the proximalshaft housing 4110 by the frame shaft 4510 and is rotatable about alongitudinal axis extending through the frame shaft 4510. The drivesystem 4700 further comprises a transfer shaft 4750 and an output shaft4780. The transfer shaft 4750 is also rotatably supported within theproximal shaft housing 4110 and is rotatable about a longitudinal axisextending parallel to, or at least substantially parallel to, the frameshaft 4510 and the longitudinal axis defined therethrough. The transfershaft 4750 comprises a proximal spur gear 4740 fixedly mounted theretosuch that the proximal spur gear 4740 rotates with the transfer shaft4750. The proximal spur gear 4740 is operably intermeshed with anannular gear face 4730 defined around the outer circumference of thedrive shaft 4710 such that the rotation of the drive shaft 4710 istransferred to the transfer shaft 4750. The transfer shaft 4750 furthercomprises a distal spur gear 4760 fixedly mounted thereto such that thedistal spur gear 4760 rotates with the transfer shaft 4750. The distalspur gear 4760 is operably intermeshed with an annular gear 4770 definedaround the outer circumference of the output shaft 4780 such that therotation of the transfer shaft 4750 is transferred to the output shaft4780. Similar to the above, the output shaft 4780 is rotatably supportedwithin the proximal shaft housing 4110 by the distal portion 4550 of theshaft frame 4500 such that the output shaft 4780 rotates about thelongitudinal shaft axis. Notably, the output shaft 4780 is not directlycoupled to the input shaft 4710; rather, the output shaft 4780 isoperably coupled to the input shaft 4710 by the transfer shaft 4750.Such an arrangement provides room for the manually-actuated jaw closureactuation system 4600 discussed below.

Further to the above, referring primarily to FIGS. 47 and 48, the jawclosure actuation system 4600 comprises an actuation, or scissors,trigger 4610 rotatably coupled to the proximal shaft housing 4110 abouta pivot 4620. The actuation trigger 4610 comprises an elongate portion4612, a proximal end 4614, and a grip ring aperture 4616 defined in theproximal end 4614 which is configured to be gripped by the clinician.The shaft assembly 4000 further comprises a stationary grip 4160extending from the proximal housing 4110. The stationary grip 4160comprises an elongate portion 4162, a proximal end 4164, and a grip ringaperture 4166 defined in the proximal end 4164 which is configured to begripped by the clinician. In use, as described in greater detail below,the actuation trigger 4610 is rotatable between an unactuated positionand an actuated position (FIG. 48), i.e., toward the stationary grip4160, to close the jaw assembly 8100 of the end effector 8000.

Referring primarily to FIG. 48, the jaw closure actuation system 4600further comprises a drive link 4640 rotatably coupled to the proximalshaft housing 4110 about a pivot 4650 and, in addition, an actuation rod4660 operably coupled to the drive link 4640. The actuation rod 4660extends through an aperture defined in the longitudinal frame portion4560 and is translatable along the longitudinal axis of the shaft frame4500. The actuation rod 4660 comprises a distal end operably coupled tothe jaw assembly 8100 and a proximal end 4665 positioned in a drive slot4645 defined in the drive link 4640 such that the actuation rod 4660 istranslated longitudinally when the drive link 4640 is rotated about thepivot 4650. Notably, the proximal end 4665 is rotatably supported withinthe drive slot 4645 such that the actuation rod 4660 can rotate with theend effector 8000.

Further to the above, the actuation trigger 4610 further comprises adrive arm 4615 configured to engage and rotate the drive link 4640proximally, and translate the actuation rod 4660 proximally, when theactuation trigger 4610 is actuated, i.e., moved closer to the proximalshaft housing 4110. In such instances, the proximal rotation of thedrive link 4640 resiliently compresses a biasing member, such as a coilspring 4670, for example, positioned intermediate the drive link 4640and the frame shaft 4510. When the actuation trigger 4610 is released,the compressed coil spring 4670 re-expands and pushes the drive link4640 and the actuation rod 4660 distally to open the jaw assembly 8100of the end effector 8000. Moreover, the distal rotation of the drivelink 4640 drives, and automatically rotates, the actuation trigger 4610back into its unactuated position. That being said, the clinician couldmanually return the actuation trigger 4610 back into its unactuatedposition. In such instances, the actuation trigger 4610 could be openedslowly. In either event, the shaft assembly 4000 further comprises alock configured to releasably hold the actuation trigger 4610 in itsactuated position such that the clinician can use their hand to performanother task without the jaw assembly 8100 opening unintentionally.

In various alternative embodiments, further to the above, the actuationrod 4660 can be pushed distally to close the jaw assembly 8100. In atleast one such instance, the actuation rod 4660 is mounted directly tothe actuation trigger 4610 such that, when the actuation trigger 4610 isactuated, the actuation trigger 4610 drives the actuation rod 4660distally. Similar to the above, the actuation trigger 4610 can compressa spring when the actuation trigger 4610 is closed such that, when theactuation trigger 4610 is released, the actuation rod 4660 is pushedproximally.

Further to the above, the shaft assembly 4000 has threefunctions—opening/closing the jaw assembly of an end effector, rotatingthe end effector about a longitudinal axis, and articulating the endeffector about an articulation axis. The end effector rotation andarticulation functions of the shaft assembly 4000 are driven by themotor assembly 1600 and the control system 1800 of the drive module 1100while the jaw actuation function is manually-driven by the jaw closureactuation system 4600. The jaw closure actuation system 4600 could be amotor-driven system but, instead, the jaw closure actuation system 4600has been kept a manually-driven system such that the clinician can havea better feel for the tissue being clamped within the end effector.While motorizing the end effector rotation and actuation systemsprovides certain advantages for controlling the position of the endeffector, motorizing the jaw closure actuation system 4600 may cause theclinician to lose a tactile sense of the force being applied to thetissue and may not be able to assess whether the force is insufficientor excessive. Thus, the jaw closure actuation system 4600 ismanually-driven even though the end effector rotation and articulationsystems are motor-driven.

FIG. 50 is a logic diagram of the control system 1800 of the surgicalsystem depicted in FIG. 1 in accordance with at least one embodiment.The control system 1800 comprises a control circuit. The control circuitincludes a microcontroller 1840 comprising a processor 1820 and a memory1830. One or more sensors, such as sensors 1880, 1890, 6180′, 6280′,6380′, 7190″, and/or 6290′″, for example, provide real time feedback tothe processor 1820. The control system 1800 further comprises a motordriver 1850 configured to control the electric motor 1610 and a trackingsystem 1860 configured to determine the position of one or morelongitudinally movable components in the surgical instrument, such asthe clutches 6110, 6120, and 6130 and/or the longitudinally-movabledrive nut 7150 of the jaw assembly drive, for example. The trackingsystem 1860 is also configured to determine the position of one or morerotational components in the surgical instrument, such as the driveshaft 2530, the outer shaft 6230, and/or the articulation drive 6330,for example. The tracking system 1860 provides position information tothe processor 1820, which can be programmed or configured to, amongother things, determine the position of the clutches 6110, 6120, and6130 and the drive nut 7150 as well as the orientation of the jaws 7110and 7120. The motor driver 1850 may be an A3941 available from AllegroMicrosystems, Inc., for example; however, other motor drivers may bereadily substituted for use in the tracking system 1860. A detaileddescription of an absolute positioning system is described in U.S.Patent Application Publication No. 2017/0296213, entitled SYSTEMS ANDMETHODS FOR CONTROLLING A SURGICAL STAPLING AND CUTTING INSTRUMENT, theentire disclosure of which is hereby incorporated herein by reference.

The microcontroller 1840 may be any single core or multicore processorsuch as those known under the trade name ARM Cortex by TexasInstruments, for example. In at least one instance, the microcontroller1840 is a LM4F230H5QR ARM Cortex-M4F Processor Core, available fromTexas Instruments, for example, comprising on-chip memory of 256 KBsingle-cycle flash memory, or other non-volatile memory, up to 40 MHz, aprefetch buffer to improve performance above 40 MHz, a 32 KBsingle-cycle serial random access memory (SRAM), internal read-onlymemory (ROM) loaded with StellarisWare® software, 2 KB electricallyerasable programmable read-only memory (EEPROM), one or more pulse widthmodulation (PWM) modules and/or frequency modulation (FM) modules, oneor more quadrature encoder inputs (QEI) analog, one or more 12-bitAnalog-to-Digital Converters (ADC) with 12 analog input channels, forexample, details of which are available from the product datasheet.

In various instances, the microcontroller 1840 comprises a safetycontroller comprising two controller-based families such as TMS570 andRM4x known under the trade name Hercules ARM Cortex R4, also by TexasInstruments. The safety controller may be configured specifically forIEC 61508 and ISO 26262 safety critical applications, among others, toprovide advanced integrated safety features while delivering scalableperformance, connectivity, and memory options.

The microcontroller 1840 is programmed to perform various functions suchas precisely controlling the speed and/or position of the drive nut 7150of the jaw closure assembly, for example. The microcontroller 1840 isalso programmed to precisely control the rotational speed and positionof the end effector 7000 and the articulation speed and position of theend effector 7000. In various instances, the microcontroller 1840computes a response in the software of the microcontroller 1840. Thecomputed response is compared to a measured response of the actualsystem to obtain an “observed” response, which is used for actualfeedback decisions. The observed response is a favorable, tuned, valuethat balances the smooth, continuous nature of the simulated responsewith the measured response, which can detect outside influences on thesystem.

The motor 1610 is controlled by the motor driver 1850. In various forms,the motor 1610 is a DC brushed driving motor having a maximum rotationalspeed of approximately 25,000 RPM, for example. In other arrangements,the motor 1610 includes a brushless motor, a cordless motor, asynchronous motor, a stepper motor, or any other suitable electricmotor. The motor driver 1850 may comprise an H-bridge driver comprisingfield-effect transistors (FETs), for example. The motor driver 1850 maybe an A3941 available from Allegro Microsystems, Inc., for example. TheA3941 driver 1850 is a full-bridge controller for use with externalN-channel power metal oxide semiconductor field effect transistors(MOSFETs) specifically designed for inductive loads, such as brush DCmotors. In various instances, the driver 1850 comprises a unique chargepump regulator provides full (>10 V) gate drive for battery voltagesdown to 7 V and allows the A3941 to operate with a reduced gate drive,down to 5.5 V. A bootstrap capacitor may be employed to provide theabove-battery supply voltage required for N-channel MOSFETs. An internalcharge pump for the high-side drive allows DC (100% duty cycle)operation. The full bridge can be driven in fast or slow decay modesusing diode or synchronous rectification. In the slow decay mode,current recirculation can be through the high-side or the lowside FETs.The power FETs are protected from shoot-through by resistor adjustabledead time. Integrated diagnostics provide indication of undervoltage,overtemperature, and power bridge faults, and can be configured toprotect the power MOSFETs under most short circuit conditions. Othermotor drivers may be readily substituted.

The tracking system 1860 comprises a controlled motor drive circuitarrangement comprising one or more position sensors, such as sensors1880, 1890, 6180′, 6280′, 6380′, 7190″, and/or 6290′″, for example. Theposition sensors for an absolute positioning system provide a uniqueposition signal corresponding to the location of a displacement member.As used herein, the term displacement member is used generically torefer to any movable member of the surgical system. In variousinstances, the displacement member may be coupled to any position sensorsuitable for measuring linear displacement. Linear displacement sensorsmay include contact or non-contact displacement sensors. Lineardisplacement sensors may comprise linear variable differentialtransformers (LVDT), differential variable reluctance transducers(DVRT), a slide potentiometer, a magnetic sensing system comprising amovable magnet and a series of linearly arranged Hall Effect sensors, amagnetic sensing system comprising a fixed magnet and a series ofmovable linearly arranged Hall Effect sensors, an optical sensing systemcomprising a movable light source and a series of linearly arrangedphoto diodes or photo detectors, or an optical sensing system comprisinga fixed light source and a series of movable linearly arranged photodiodes or photo detectors, or any combination thereof.

The position sensors 1880, 1890, 6180′, 6280′, 6380′, 7190″, and/or6290′″, for example, may comprise any number of magnetic sensingelements, such as, for example, magnetic sensors classified according towhether they measure the total magnetic field or the vector componentsof the magnetic field. The techniques used to produce both types ofmagnetic sensors encompass many aspects of physics and electronics. Thetechnologies used for magnetic field sensing include search coil,fluxgate, optically pumped, nuclear precession, SQUID, Hall-Effect,anisotropic magnetoresistance, giant magnetoresistance, magnetic tunneljunctions, giant magnetoimpedance, magnetostrictive/piezoelectriccomposites, magnetodiode, magnetotransistor, fiber optic, magnetooptic,and microelectromechanical systems-based magnetic sensors, among others.

In various instances, one or more of the position sensors of thetracking system 1860 comprise a magnetic rotary absolute positioningsystem. Such position sensors may be implemented as an AS5055EQFTsingle-chip magnetic rotary position sensor available from AustriaMicrosystems, AG and can be interfaced with the controller 1840 toprovide an absolute positioning system. In certain instances, a positionsensor comprises a low-voltage and low-power component and includes fourHall-Effect elements in an area of the position sensor that is locatedadjacent a magnet. A high resolution ADC and a smart power managementcontroller are also provided on the chip. A CORDIC processor (forCoordinate Rotation Digital Computer), also known as the digit-by-digitmethod and Volder's algorithm, is provided to implement a simple andefficient algorithm to calculate hyperbolic and trigonometric functionsthat require only addition, subtraction, bitshift, and table lookupoperations. The angle position, alarm bits, and magnetic fieldinformation are transmitted over a standard serial communicationinterface such as an SPI interface to the controller 1840. The positionsensors can provide 12 or 14 bits of resolution, for example. Theposition sensors can be an AS5055 chip provided in a small QFN 16-pin4×4×0.85 mm package, for example.

The tracking system 1860 may comprise and/or be programmed to implementa feedback controller, such as a PID, state feedback, and adaptivecontroller. A power source converts the signal from the feedbackcontroller into a physical input to the system, in this case voltage.Other examples include pulse width modulation (PWM) and/or frequencymodulation (FM) of the voltage, current, and force. Other sensor(s) maybe provided to measure physical parameters of the physical system inaddition to position. In various instances, the other sensor(s) caninclude sensor arrangements such as those described in U.S. Pat. No.9,345,481, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM,which is hereby incorporated herein by reference in its entirety; U.S.Patent Application Publication No. 2014/0263552, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, which is hereby incorporatedherein by reference in its entirety; and U.S. patent application Ser.No. 15/628,175, entitled TECHNIQUES FOR ADAPTIVE CONTROL OF MOTORVELOCITY OF A SURGICAL STAPLING AND CUTTING INSTRUMENT, which is herebyincorporated herein by reference in its entirety. In a digital signalprocessing system, absolute positioning system is coupled to a digitaldata acquisition system where the output of the absolute positioningsystem will have finite resolution and sampling frequency. The absolutepositioning system may comprise a compare and combine circuit to combinea computed response with a measured response using algorithms such asweighted average and theoretical control loop that drives the computedresponse towards the measured response. The computed response of thephysical system takes into account properties like mass, inertial,viscous friction, inductance resistance, etc., to predict what thestates and outputs of the physical system will be by knowing the input.

The absolute positioning system provides an absolute position of thedisplacement member upon power up of the instrument without retractingor advancing the displacement member to a reset (zero or home) positionas may be required with conventional rotary encoders that merely countthe number of steps forwards or backwards that the motor 1610 has takento infer the position of a device actuator, drive bar, knife, and thelike.

A sensor 1880 comprising a strain gauge or a micro-strain gauge, forexample, is configured to measure one or more parameters of the endeffector, such as, for example, the strain experienced by the jaws 7110and 7120 during a clamping operation. The measured strain is convertedto a digital signal and provided to the processor 1820. In addition toor in lieu of the sensor 1880, a sensor 1890 comprising a load sensor,for example, can measure the closure force applied by the closure drivesystem to the jaws 7110 and 7120. In various instances, a current sensor1870 can be employed to measure the current drawn by the motor 1610. Theforce required to clamp the jaw assembly 7100 can correspond to thecurrent drawn by the motor 1610, for example. The measured force isconverted to a digital signal and provided to the processor 1820. Amagnetic field sensor can be employed to measure the thickness of thecaptured tissue. The measurement of the magnetic field sensor can alsobe converted to a digital signal and provided to the processor 1820.

The measurements of the tissue compression, the tissue thickness, and/orthe force required to close the end effector on the tissue as measuredby the sensors can be used by the controller 1840 to characterize theposition and/or speed of the movable member being tracked. In at leastone instance, a memory 1830 may store a technique, an equation, and/or alook-up table which can be employed by the controller 1840 in theassessment. In various instances, the controller 1840 can provide theuser of the surgical instrument with a choice as to the manner in whichthe surgical instrument should be operated. To this end, the display1440 can display a variety of operating conditions of the instrument andcan include touch screen functionality for data input. Moreover,information displayed on the display 1440 may be overlaid with imagesacquired via the imaging modules of one or more endoscopes and/or one ormore additional surgical instruments used during the surgical procedure.

As discussed above, the drive module 1100 of the handle 1000 and/or theshaft assemblies 2000, 3000, 4000, and/or 5000, for example, attachablethereto comprise control systems. Each of the control systems cancomprise a circuit board having one or more processors and/or memorydevices. Among other things, the control systems are configured to storesensor data, for example. They are also configured to store data whichidentifies the shaft assembly to the handle 1000. Moreover, they arealso configured to store data including whether or not the shaftassembly has been previously used and/or how many times the shaftassembly has been used. This information can be obtained by the handle1000 to assess whether or not the shaft assembly is suitable for useand/or has been used less than a predetermined number of times, forexample.

Further to the above, the first module connector 1120 of the drivemodule 1100 comprises a side battery port defined in the side of thedrive module 1100. Similarly, the second module connector 1120′comprises a proximal battery port defined in the proximal end of thedrive module 1100. That said, a drive module can comprise a battery portat any suitable location. In any event, the power module 1200 isoperably attachable to the drive module 1100 at the side battery port1120, as illustrated in FIGS. 54-58, or the proximal battery port 1120′,as illustrated in FIGS. 67 and 68. This is possible because theconnector 1220 of the power module 1200 is compatible with the sidebattery port 1120 and the proximal battery port 1120′. Among otherthings, the connector 1220 comprises a substantially circular, orsubstantially cylindrical, configuration that matches, or at leastsubstantially matches, the substantially circular, or substantiallycylindrical, configurations of the battery ports 1120 and 1120′. Invarious instances, the connector 1220 comprises a frustoconical, or anat least substantially frustoconical, shape having a bottom portionwhich is larger than the top portion and an angled, or tapered, sideextending therebetween. The above being said, the connector 1220 of thepower module 1200 does not comprise keys, or projections, extendingtherefrom which interfere with the assembly of the power module 1200 tothe battery ports 1120 and 1120′.

Referring primarily to FIGS. 55 and 56, the connector 1220 comprises twolatches 1240 extending therefrom. The latches 1240 are positioned onopposite sides of the connector 1220 such that they comprise opposinglatch shoulders which releasably hold the power module 1200 to thehandle module 1100. The side battery port 1120 comprises latch openings1125 defined in the housing 1100 which are configured to receive thelatches 1240 of the power module 1200 and, similarly, the proximalbattery port 1120′ comprises latch openings 1125′ defined in the housing1100 which are also configured to receive the latches 1240 of the powermodule 1200. While the latch openings 1125 in the side battery port 1120and the latch openings 1125′ in the proximal battery port 1120′ limitthe orientations in which the power module 1200 can be assembled to eachbattery port 1120 and 1120′, i.e., two orientations for each batteryport, the power module 1200 is nonetheless operably attachable to bothbattery ports 1120 and 1120′.

Further to the above, the latches 1240 of the power module 1200 areconfigured to engage the drive module 1100 in a snap-fit manner. Invarious instances, the latches 1240 resiliently flex radially outwardlywhen the power module 1200 is assembled to the drive module 1100 andthen resiliently move, or snap, radially inwardly once the power module1200 is fully seated within one of the ports 1120 and 1120′ to lock thepower module 1200 to the drive module 1100. In various instances, thelatches 1240 comprise flexible arms which deflect radially inwardly andoutwardly as described above while, in some instances, the latches 1240comprise one or more biasing members, such as springs, for example,configured to resiliently push the latches 1240 into their inward, orlocked, positions. In various embodiments, the power module 1200 cancomprise members which are press-fit into apertures defined in the ports1120 and 1120′ to retain the power module 1200 to the drive module 1100.

Further to the above, the electrical contacts of the power module 1200are defined on the top portion, or face, of the connector 1220. Asdiscussed above, the electrical contacts of the power module 1200 engagecorresponding electrical contacts defined in the ports 1120 and 1120′when the power module 1200 is attached to the drive module 1100 to placethe power module 1200 in electrical communication with the drive module1100. In various instances, the electrical contacts of the power module1200 are compressed against the electrical contacts of the drive module1100 when the power module 1200 is attached to the drive module 1100. Inat least one such instance, the power module contacts and/or the drivemodule contacts comprise resilient members which are configured toelastically deflect when the power module 1200 is attached to the drivemodule 1100. Such resilient members, along with the latches 1240, canassure that there is an adequate electrical interface between the powermodule 1200 and the drive module 1100. In alternative embodiments, thepower module 1200 can comprise annular electrical contacts extendingaround the perimeter thereof which engage electrical contacts on thesides of the ports 1120 and 1120′. Such an arrangement could permitrelative rotation between the power module 1200 and the drive module1100.

Further to the above, the power module 1300 is operably attachable tothe drive module 1100 at the proximal battery port 1120′, as illustratedin FIGS. 59-66, but not the side battery port 1120, as illustrated inFIGS. 69 and 70. This is the case because the connector 1320 of thepower module 1300 is compatible with the proximal battery port 1120′,but not the side battery port 1120. Although the connector 1320comprises a substantially circular, or substantially cylindrical,configuration that matches, or at least substantially matches, thesubstantially circular, or substantially cylindrical, configurations ofthe battery ports 1120 and 1120′, the connector 1320 of the power module1300 comprises keys, or projections, 1315 extending therefrom whichinterfere with the assembly of the power module 1300 to the side batteryport 1120, but not the proximal battery port 1120′. When a clinicianattempts to assembly the power module 1300 to the side battery port1120′, the projections 1315 contact the housing 1110 and prevent thelatches 1340 of the power module 1300 from locking the power module 1300to the drive module 1100 and prevent the power module 1300 from beingelectrically coupled to the drive module 1100. That being said,referring primarily to FIGS. 63 and 64, the proximal battery port 1120′comprises clearance apertures 1115′ defined therein configured toreceive the projections 1315 of the power module 1300 and permit thepower module 1300 to be assembled to the proximal battery port 1120′.Similar to the above, the latch openings 1125′ and the clearanceapertures 1115′ in the proximal battery port 1120′ limit theorientations in which the power module 1300 can be assembled to theproximal battery port 1120′ to two orientations.

Further to the above, other circumstances can prevent the attachment ofa power module to one of the battery ports 1120 and 1120′. For instance,one of the battery ports can have an asymmetrical geometry which isconfigured to receive a complementary geometry of only one of the powermodules. In at least one such instance, the side battery port 1120 cancomprise a semicircular cavity and the proximal battery port 1120′ cancomprise a circular cavity, wherein the connector 1220 of the powermodule 1200 comprises a semicircular geometry which can be received inboth of the battery ports 1120 and 1120′ while the connector 1320 of thepower module 1300 comprises a circular geometry which can be received inthe proximal battery port 1120′, but not the side battery port 1120. Insome instances, the configuration of the shaft assembly attached to thedrive module 1100 can prevent the assembly of one of the power modulesto the drive module 1100. For instance, referring to FIG. 59, the shaftassembly 4000, for example, can prevent the assembly of the power module1300 to the side battery port 1120 as the actuation trigger 4610interferes with its assembly thereto. Notably, such an arrangement wouldalso prevent the power module 1200 from being assembled to the sidebattery port 1120. As a result, the clinician would be required to usethe proximal battery port 1120′ to couple a power module to the drivemodule 1100 when using the shaft assembly 4000. The configuration ofcertain shaft assemblies, referring to FIGS. 71 and 72, would permitboth of the power modules 1200 and 1300 to be assembled to the drivemodule 1100 at the same time. For instance, referring to FIG. 51, theshaft assembly 3000 of FIG. 1 would permit both of the power modules1200 and 1300 to be used to supply power to the drive module 1100simultaneously.

The power modules 1200 and 1300 are configured to supply power to thedrive module 1100 at the same, or at least substantially the same,voltage. For instance, each power module 1200 and 1300 is configured tosupply power to the drive module 1100 at 3 VDC, for example. The controlsystem 1800 of the drive module 1100 comprises one or more powerinverters, for example, configured to convert the DC current to ACcurrent to the extent that AC current is needed. That said, the powermodules 1200 and 1300 can be configured to deliver power to the drivemodule 1100 at any suitable voltage. In at least one instance, the powermodules 1200 and/or 1300 are configured to deliver AC power to the drivemodule. In at least one such instance, the power modules 1200 and/or1300 each comprise one or more power inverters. In alternativeembodiments, the power modules 1200 and 1300 are configured to supplypower to the drive module 1100 at different voltages. In suchembodiments, the configurations of the ports 1120 and 1120′, discussedabove, can prevent a power module having a higher voltage from beingattached to a lower voltage port. Likewise, the configurations of theports 1120 and 1120′ can prevent a power module having a lower voltagefrom being attached to a higher voltage port, if desired.

In various instances, the power modules 1200 and 1300 are configured toprovide the same, or at least substantially the same, current to thedrive module. In at least one instance, the power modules 1200 and 1300supply the same, or at least substantially the same, magnitude ofcurrent to the drive module 1100. In alternative embodiments, the powermodules 1200 and 1300 are configured to provide different currents tothe drive module 1100. In at least one instance, the power module 1200provides a current to the drive module 1100 having a magnitude which istwice that of the current provided by the power module 1300, forexample. In at least one such instance, the battery cells of the powermodule 1200 are arranged in parallel to provide the same voltage as thepower module 1300 but at twice the current. Similar to the above, theconfigurations of the ports 1120 and 1120′, discussed above, can preventa power module having a higher current from being attached to a lowercurrent port. Likewise, the configurations of the ports 1120 and 1120′can prevent a power module having a lower current from being attached toa higher current port, if desired.

Further to the above, the control system 1800 is configured toadaptively manage the power provided by the power modules 1200 and 1300.In various instances, the control system 1800 comprises one or moretransformer circuits configured to step up and/or step down the voltageprovided to it by a power module. For instance, if a higher voltagepower module is attached to a lower voltage port, the control system1800 can activate, or switch on, a transformer circuit to step down thevoltage from the higher voltage power module. Similarly, if a lowervoltage power module is attached to a higher voltage port, the controlsystem 1800 can activate, or switch on, a transformer circuit to step upthe voltage from the lower voltage power module. In various embodiments,the control system 1800 is configured to switch a power module off if apower module having an inappropriate voltage is attached to a port inthe drive module 1100. In at least one instance, the control system 1800comprises one or more voltmeter circuits configured to evaluate thevoltage of a power module attached to the drive module and, if thevoltage of the power module is incorrect or outside of an appropriatevoltage range, the control system 1800 can switch off the power modulesuch that the power module does not supply power to the drive module1100. In at least one such instance, the drive module 1100 has avoltmeter circuit for each port 1120 and 1120′. In at least oneinstance, the control system 1800 comprises one or more ammeter circuitsconfigured to evaluate the current of a power module attached to thedrive module and, if the current of the power module is incorrect oroutside of an appropriate current range, the control system 1800 canswitch off the power module such that the power module does not supplypower to the drive module 1100. In at least one such instance, the drivemodule 1100 has a ammeter circuit for each port 1120 and 1120′. In atleast one instance, each power module 1200 and 1300 comprises a switchcircuit which, when opened by the control system 1800, prevents powerfrom being supplied to the drive module 1100. If a power modulecomprises the correct voltage or a voltage within an appropriate voltagerange for the port in which the power module is attached, the switchcircuit remains closed and/or is closed by the control system 1800. Inat least one such instance, the drive module 1100 has a switch circuitfor each port 1120 and 1120′.

In various instances, a power module can comprise a switch which isselectively actuatable by the clinician to prevent the power module fromsupplying power to the drive module 1100. In at least one instance, theswitch comprises a mechanical switch, for example, in the power supplycircuit of the power module. A power module that has been switched off,however, can still provide other benefits. For instance, a switched-offpower module 1200 can still provide a pistol grip and a switched-offpower module 1300 can still provide a wand grip. Moreover, in someinstances, a switched-off power module can provide a power reserve thatcan be selectively actuated by the clinician.

In addition to or in lieu of the above, each of the power modules 1200and 1300 comprises an identification memory device. The identificationmemory devices can comprise a solid state chip, for example, having datastored thereon which can be accessed by and/or transmitted to thecontrol system 1800 when a power module is assembled to the drive module1100. In at least one instance, the data stored on the identificationmemory device can comprise data regarding the voltage that the powermodule is configured to supply to the drive module 1100, for example.

Further to the above, each of the shaft assemblies 2000, 3000, 4000,and/or 5000 comprise an identification memory device, such as memorydevice 2830, for example. The identification memory device of a shaftassembly can comprise a solid state chip, for example, having datastored thereon which can be accessed by and/or transmitted to thecontrol system 1800 when the shaft assembly is assembled to the drivemodule 1100. In at least one instance, the data stored on theidentification memory device can comprise data regarding the powerrequired to operate the drive systems of the shaft assembly. The shaftassembly 2000 comprises three systems driven by the drive module1100—the end effector articulation drive system, the end effectorrotation drive system, and the jaw drive system—each of which havingtheir own power requirement. The jaw drive system, for instance, mayrequire more power than the end effector articulation and rotation drivesystems. To this end, the control system 1800 is configured to verifythat the power provided by the power module, or power modules, attachedto the drive module 1100 is sufficient to power all of the drivesystems—including the jaw drive system—of the shaft assembly 2000assembled to the drive module 1100. As such, the control system 1800 isconfigured to assure that the power module arrangement attached to thedrive module 1100 is properly paired with the shaft assembly attached tothe drive module 1100. If the power provided by the power modulearrangement is insufficient, or below a required power threshold, thecontrol system 1800 can inform the clinician that a different and/or anadditional power module is required. In at least one instance, the drivemodule 1100 comprises a low-power indicator on the housing 1110 and/oron the display screen 1440, for example. Notably, the jaw drive systemof the shaft assembly 4000 is not driven by the drive module 1100;rather, it is manually powered by the clinician. As such, the powerrequired to operate the shaft assembly 4000 can be less than the powerrequired to operate the shaft assembly 2000, for example, and thecontrol system 1800 can lower the required power threshold for the shaftassembly 4000 when evaluating the power module arrangement.

Further to the above, an end effector configured to grasp and/or dissecttissue may require less power than an end effector configured to clipthe tissue of a patient. As a result, an end effector and/or shaftassembly comprising a clip applier may have a larger power requirementthan an end effector and/or shaft assembly comprising grasping and/ordissecting jaws. In such instances, the control system 1800 of the drivemodule 1100 is configured to verify that the power module, or modules,attached to the drive module 1100 can provide sufficient power to thedrive module 1100. The control system 1800 can be configured tointerrogate the identification chips on the power modules attached tothe drive module 1100 and/or evaluate the power sources within the powermodules to assess whether the power modules comprisesufficiently-available voltage and/or current to properly power thedrive module 1100 to operate the clip applier.

Further to the above, an end effector configured to grasp and/or dissecttissue may require less power than an end effector configured to suturethe tissue of a patient, for example. As a result, an end effectorand/or shaft assembly comprising a suturing device may have a largerpower requirement than an end effector and/or shaft assembly comprisinggrasping and/or dissecting jaws. In such instances, the control system1800 of the drive module 1100 is configured to verify that the powermodule, or modules, attached to the drive module 1100 can providesufficient power to the drive module 1100 based on the shaft assemblyattached to the drive module 1100. The control system 1800 can beconfigured to interrogate the identification chips on the power modulesattached to the drive module 1100 and/or evaluate the power sourceswithin the power modules to assess whether the power modules comprisesufficiently-available voltage and/or current to properly power thedrive module 1100 to operate the suturing device.

In addition to or in lieu of the above, an end effector, such as endeffector 7000, for example, comprises an identification memory device.The identification memory device of an end effector can comprise a solidstate chip, for example, having data stored thereon which can beaccessed by and/or transmitted to the control system 1800 when the endeffector is assembled to the drive module 1100 by way of a shaftassembly. In at least one instance, the data stored on theidentification memory device can comprise data regarding the powerrequired to operate the drive systems of the end effector. The endeffector can be in communication with the drive module 1100 throughelectrical pathways, or circuits, extending through the shaft assembly.Similar to the above, the end effector can identify itself to the drivemodule 1100 and, with this information, the drive module 1100 can adaptits operation to properly operate the end effector.

As described above, the power modules 1200 and 1300 each comprise one ormore battery cells. That said, the power modules 1200 and 1300 cancomprise any suitable means for storing and delivering power. In atleast one instance, the power modules 1200 and 1300 comprise capacitorsand/or supercapacitors configured to store energy and deliver energy tothe drive module 1100. The capacitors and/or supercapacitors can be partof the same electrical circuit as the battery cells or a differentelectrical circuit. A supercapacitor can comprise electrostaticdouble-layer capacitance and/or electrochemical pseudocapacitance, bothof which can contribute to the total capacitance of the supercapacitor.In various instances, electrostatic double-layer capacitors use carbonelectrodes or derivatives with much higher electrostatic double-layercapacitance than electrochemical pseudocapacitance, achieving separationof charge in a Helmholtz double layer at the interface between thesurface of a conductive electrode and an electrolyte. The separation ofcharge is often of the order of a few angstroms (0.3-0.8 nm), muchsmaller than in a conventional capacitor. Electrochemicalpseudocapacitors use metal oxide or conducting polymer electrodes with ahigh amount of electrochemical pseudocapacitance additional to thedouble-layer capacitance. Pseudocapacitance is achieved by Faradaicelectron charge-transfer with redox reactions, intercalation, and/orelectrosorption. Hybrid capacitors, such as a lithium-ion capacitor, forexample, could also be used which comprise electrodes with differingcharacteristics—one exhibiting mostly electrostatic capacitance and theother mostly electrochemical capacitance.

The power modules 1200 and 1300 can be rechargeable or non-rechargeable.When the power modules 1200 and 1300 are not rechargeable, they aredisposed of after a single use. In such instances, it is desirable forthe power modules 1200 and 1300 to be completely drained, or at leastsubstantially drained, of power when they are disposed of. To this end,each power module comprises a drain which is engaged, or actuated, whenthe power module is assembled to the drive module 1100. In variousinstances, the drain comprises a resistance circuit inside the powermodule that includes the battery cells. Once actuated, the drain slowlydischarges the battery cells of the power module, but at a rate whichstill permits the power module to provide sufficient power to the drivemodule 1100 during the surgical procedure. After the surgical procedureis completed, however, the drain continues to discharge the batterycells even though the power module may no longer be assembled to thedrive module 1100. As such, the drain discharges the battery cellswhether or not the power module is supplying power to, or attached to,the drive module 1100. The entire disclosures of U.S. Pat. No.8,632,525, entitled POWER CONTROL ARRANGEMENTS FOR SURGICAL INSTRUMENTSAND BATTERIES, which issued on Jan. 21, 2014, and U.S. Pat. No.9,289,212, entitled SURGICAL INSTRUMENTS AND BATTERIES FOR SURGICALINSTRUMENTS, which issued on Mar. 22, 2016, are incorporated byreference herein.

Multiple surgical instruments, including various handheld instruments,are used by a clinician during a particular surgical procedure toperform different functions. Each surgical instrument may comprisedifferent handle and/or grip configurations in addition to differentuser control mechanisms. Switching between various handheld instrumentsmay cause delay and/or discomfort, as the clinician regains control overthe surgical instrument and actuates the user control mechanism(s). Theuse of numerous powered surgical instruments may require a user toensure that, prior to the start of every surgical procedure, numerouspower sources are charged and/or functional, as power sources may varyand/or may not compatible with all powered surgical instruments.

A modular surgical instrument comprising a universal handle and powersource may provide a clinician with a sense of familiarity in using auniversal handle configuration. The modular surgical instrument isconfigured for use with numerous surgical tool attachments. Instead ofhaving to charge a plurality of different power sources, the modularsurgical instrument is configured for use with a replaceable powersource that can be discarded after each surgical procedure. Furthermore,the use of one universal handle with a plurality of surgical toolattachments may reduce the clutter and/or volume of surgical instrumentswithin the surgical arena.

FIG. 73 illustrates a portion of a modular surgical instrument 80000 andFIG. 74 illustrates an electrical architecture of the modular surgicalinstrument 80000. The configuration of the modular surgical instrument80000 is similar in many respects to the surgical instrument 1000 inFIG. 1 discussed above. The modular surgical instrument 80000 comprisesa plurality of modular components, including, for example: a drivemodule 80010, a shaft 80020, an end effector 80030, and a power source80040. In various instances, the drive module 80010 comprises a handle.The drive module 80010 comprises one or more control switches 80012 anda motor 80015.

The shaft 80020 comprises a control circuit 80022 configured tofacilitate communication between the modular components 80010, 80020,80030, 80040 of the surgical instrument 80000. The operation andfunctionality of the modular components 80010, 80020, 80030, 80040 ofthe surgical instrument 80000 are described in greater detail above inconnection with other surgical instruments.

In various instances, the one or more control switches 80012 correspondto the rotation actuator 1420 and the articulation actuator 1430 of theinput system 1400 as described in greater detail with respect to FIGS. 7and 8 above. As shown in FIGS. 7 and 8, the articulation actuator 1430comprises a first push button 1432 and a second push button 1434. Thefirst push button 1432 comprises a first switch that is closed when thefirst push button 1434 is depressed. Similar in many aspects to thearticulation actuator 1430 and the rotation actuator 1420 shown in FIGS.7 and 8, the one or more control switches 80012 may comprise pushbuttons. When a user input depresses the push button, a switch is closedthat sends a signal to the control circuit 80022 indicative of a usercommand. In various instances, a first push button can initiatearticulation or rotation in a first direction while a second push buttoncan initiate articulation or rotation in a second direction. Theoperation and functionality of these control switches 80012 aredescribed in greater detail above.

In various instances, the shaft 80020 is configured to be disposableafter being used to treat a patient. In such instances, the shaft 80020is usable more than once on the same patient. As discussed in moredetail below, the shaft 80020 comprises a processor 80024 and a memorystoring instructions for one or more control programs. The disposableshaft 80020 comprises any signal processing circuits required tointerface with the end effector 80030, the power source 80040, and/orthe drive module 80010 when the modular surgical instrument 80000 isfully configured, or assembled. The end effector 80030 comprises asensor array 80035 configured to monitor a parameter of the end effector80030. Such a sensor array 80035 can detect, for example, informationpertaining to the identity of the end effector 80030, an operatingstatus of the end effector 80030, and/or information regarding theenvironment of the surgical site, such as tissue properties, forexample. In various instances, the power source 80040 comprises areplaceable battery pack configured to be attached directly to the drivemodule 80010 to supply power to the surgical instrument 80000. The powersource 80040 comprises a battery 80042 and a display 80044. In variousinstances the display 80044 comprises a touch-sensitive display, forexample, wherein a user input is sent to the processor 80024.

In various instances, the drive module 80010 comprises a power sourceinterface for attaching the modular power source 80040 thereto. Thereplaceable connection between the power source 80040 and the drivemodule 80010 allows for a user to readily change out the power source80040 without having to disassemble a housing of the drive module 80010.The battery 80042 within the modular power source 80040 comprises aprimary cell, but can also include secondary cells. The primary cellbattery 80042 is configured to be fully charged once. In other words,the primary cell battery 80042 is configured to be discarded after eachsurgical procedure. Use of a disposable power supply may, among otherthings, provide assurance to the clinician that the battery 80042 isfully charged at the beginning of each surgical procedure.

The power source interface supplies the interconnection between thebattery 80042 and the connection of the display 80044 upon theattachment of the power source 80040 to the drive module 80010. In otherwords, no continuous circuits are present within the power source 80040until the power source 80040 is replaceably attached to the power sourceinterface on the drive module 80010. As such, the power source 80040 canbe distributed and sterilized in an uncoupled state. The ability to bein an uncoupled state permits each power source 80040 to be easilysterilized. For example, the modular power source 80040 is compatiblewith both ethylene oxide and gamma sterilization as no continuouscircuits are present in the unattached power source 80040.

Similar to the power source 80040, the drive module 80010 does not haveany continuous circuits while unattached to the shaft 80020 and thepower source 80040. For at least this reason, the drive module 80010 isable to be sterilized using any desired sterilization protocol followingeach use. In its unattached configuration, the drive module 80010 isconfigured to be tolerant of full immersion during the cleaning process.

Further to the above, the control circuit 80022 of the shaft 80020comprises a processor 80024 configured to receive a user input from theone or more control switches 80012 on the drive module 80010. The shaft80020 further comprises a motor controller 80028 configured to controlthe motor 80015 within the drive module 80010 when the shaft 80020 isassembled to the drive module 80010. In various instances, the controlcircuit 80022 further comprises a safety processor 80024 comprising twocontroller-based families such as, for example, TMS570 and RM4x knownunder the trade name Hercules ARM Cortex R4, by Texas Instruments. Thesafety processor 80026 may be configured specifically for IEC 61508 andISO 26262 safety critical applications, among others, to provideadvanced integrated safety features while delivering scalableperformance, connectivity, and memory options. The safety processor80026 is configured to be in signal communication with the processor80024 and the motor controller 80028. The motor controller 80028 isconfigured to be in signal communication with the sensor array 80035 ofthe end effector 80030 and the motor 80015 within the handle 80010. Themotor controller 80028 is configured to send an electrical signal, suchas, for example, a voltage signal, indicative of the voltage (or power)to be supplied to the motor 80015. The electrical signal may bedetermined based off of, for example, user input from the one or morecontrol switches 80012, input received from the sensor array 80035, userinput from the display 80044, and/or feedback from the motor 80015. Invarious instances, the motor controller 80028 may output a PWM controlsignal to the motor 80015 in order to control the motor 80015.

The shaft 80020 further comprises a memory configured to store controlprograms which, when executed, prompt the processor to, among otherthings, command the motor controller 80028 to activate the motor 80015at a pre-determined level. The memory within the control circuit 80022of each shaft 80020 is configured to store one or more control programsto permit the modular surgical instrument 80000, when fully configured,to perform a desired function. In various instances, the shaft 80020 maycomprise a default control program for when the attached shaft 80020does not comprise a control program and/or a stored control programcannot be read or detected. Such a default control program permits themotor 80015 to be run at a minimum level to allow a clinician to performbasic functions of the modular surgical instrument 80000. In variousinstances, only basic functions of the modular surgical instrument 80000are available in the default control program and are performed in amanner that minimizes harm to the tissue in and/or surrounding thesurgical site. Storing control program(s) specific to an intendedfunction in each replaceable shaft 80020 minimizes the amount ofinformation that needs to be stored and, thus, relieves the drive module80010 of the burden of storing all possible control programs, many ofwhich go unused. In various instances, the modular components 80010,80020, 80030, 80040 of the surgical instrument 80000 can be designed,manufactured, programmed, and/or updated at different times and/or inaccordance with different software and/or firmware revisions andupdates. Furthermore, individual control programs can be updated morequickly than a collection of numerous control programs. The fasterupdate time makes it more likely that clinicians and/or assistants willupdate the control program(s) to utilize the most up-to-date program ineach surgical procedure. In various instances, the drive module 80010may not comprise any control programs. In other instances, the drivemodule 80010 may comprise a default control program as discussed above.In other words, if a clinician intends to perform a first function, theclinician may attach a first shaft comprising a stored first controlprogram to the modular surgical instrument. If the clinician intends toperform a second function that is different from the first function, theclinician may remove the first shaft from the universal drive module andattach a second shaft comprising a stored second control program to themodular surgical instrument. In various instances, if the clinicianattaches a shaft without a detectable and/or functional stored controlprogram, the drive module 80010 may comprise a memory storing a defaultcontrol program to operate the modular surgical instrument 80000 atminimum levels and/or at any suitable level of functionality. Theoperation and functionality of the stored control programs are describedin greater detail in U.S. patent application Ser. No. 14/226,133, nowU.S. Patent Application Publication No. 2015/0272557, entitled MODULARSURGICAL INSTRUMENT SYSTEM, which is incorporated in its entiretyherein.

FIG. 75 depicts a drive module 80110 comprising a plurality of drivesconfigured to interact with corresponding drives in an attached shaft toproduce a desired function, such as, for example, rotation and/orarticulation of an end effector. For example, the drive module 80110comprises a rotation drive 80120 configured to rotate an end effectorupon actuation. The drive module 80110 of FIG. 75 is configured tooperate based on the type of handle attached to the modular shaft. Oneor more of the plurality of drives is decoupled when a low-functionalityhandle, such as, for example, a scissor grip handle, is attached to themodular shaft. For example, during the attachment of a low-functionalityhandle to the modular shaft, an extending lug on the low-functionalityhandle may cause the rotation drive 80120 to advance distally out ofengagement with the low-functionality handle. Such distal advancementresults in a decoupling of the rotation drive 80120 from the handle,effectively locking out the functionality of the rotation drive 80120.Upon detachment of the scissor grip handle from the modular shaft, aresilient member 80125, such as, for example, a spring, biases therotation drive 80120 proximally into its original position. In variousinstances, all of the drives are decoupled upon the attachment of thelow-functionality handle to the modular shaft. In other instances, afirst drive, such as, for example, the rotation drive 80120, may bedecoupled upon the attachment of the low-functionality handle to themodular shaft, while a second drive 80130 remains in engagement for usewith the low-functionality handle.

In various instances, the rotation drive 80120 is in communication witha manual rotation actuator, such as the rotation actuator 1420 describedin more detail above with respect to FIGS. 8, 10, and 11. As a clinicianrotates the rotation actuator, the position of the rotation actuator canbe monitored. For instance, the surgical instrument can comprise anencoder system configured to monitor the position of the rotationactuator. In addition to or in lieu of the encoder system, the drivemodule 80110 can comprise a sensor system configured to detect a degreeof rotation of the rotation actuator. In any event, the detectedposition of the rotation actuator is communicated to a processor and amotor controller, such as processor 80024 and motor controller 80028within the shaft 80020. In various instances, the drive module 80110comprises a handle.

The processor 80024 and the motor controller 80028 are configured todrive a system of the shaft 80020 other than the system being manuallydriven by the rotation drive 80120 in response to the movement of therotation drive 80120. In at least one instance, a surgical instrumenthas a first rotation joint and a second rotation joint where therotation of the surgical instrument about the first rotation joint ismanually driven and the rotation of the surgical instrument about thesecond rotation joint is driven by an electric motor. In such aninstance, the processor 80024 can monitor the rotation of the surgicalinstrument about the first rotation joint using the encoder and rotatethe surgical instrument about the second rotation joint using the motorcontroller 80028 in order to keep the rotatable components of thesurgical instrument aligned, for example.

FIG. 76 depicts a handle 80210 prior to engagement with aninterchangeable shaft 80220. The handle 80210 is usable with severalinterchangeable shafts and can be referred to as a universal handle. Theshaft 80220 comprises a drive rod 80250 configured to mechanicallyengage a distal nut 80255 of the handle 80210. A proximal end 80251 ofthe drive rod 80250 comprises a specific geometry configured to fitwithin a recess 80256 defined in the distal end of the distal nut 80255.The recess 80256 within the distal nut 80255 comprises a geometry thatis complementary of the geometry of the proximal end 80251 of the driverod 80250. In other words, once the clinician and/or the assistant hasoriented the shaft 80220 in a manner that allows for the drive rod 80250to fit within the recess on the distal nut 80255 of the handle 80210,the interchangeable shaft 80220 is successfully aligned with theuniversal handle 80210 such that there is little, if any, relativelateral movement between the distal nut 80255 and the drive rod 80250.

In various instances, the distal end 80211 of the drive nut 80255 andthe proximal end 80223 of the drive rod 80250 comprise a plurality ofmagnetic elements 80260, 80265, 80270 configured to facilitate alignmentof the shaft 80220 with the handle 80210 in addition to or in lieu ofthe mechanical alignment system described above. The system of magneticelements 80260, 80265, 80270 allows for self-alignment of the shaft80220 with the handle 80210. In various instances, the plurality ofmagnetic elements 80260, 80265, 80270 are permanent magnets. As seen inFIG. 75, the proximal end 80223 of the shaft 80220 comprises a pluralityof magnetic elements 80260, 80265 that are oriented asymmetrically,although the magnetic elements 80260, 80265 may be arranged in anysuitable manner. The magnetic elements 80260, 80265 are positioned withopposing poles facing outward from the proximal end 80223 of the shaft80220. More specifically, the magnetic elements 80260 positioned on afirst portion of the shaft 80220 are positioned with their positivepoles facing outward from the proximal end 80223, while the magneticelements 80265 positioned on a second, or opposite, portion of the shaft80220 are positioned with their negative poles facing outward from theproximal end 80223. The distal end 80211 of the drive nut 80255comprises a plurality of magnetic elements 80270 positioned with theirnegative poles facing outward from the distal end 80211 of the handle80210. Such an asymmetric pattern of magnetic elements 80260, 80265 onthe shaft 80220 can permit the shaft 80220 and the handle 80210 to bealigned at one or more predefined locations, as described in greaterdetail below. The use of magnetic elements 80260, 80265, 80270eliminates the need for a spring mechanism to shift the handle 80210 andthe shaft 80220 into predetermined positions.

Further to the above, if the clinician attempts to align the handle80210 with the shaft 80220 such that the magnetic elements 80270positioned on the handle 80210 are within the vicinity of the magneticelements 80260 positioned on a first portion of the shaft 80220, themagnetic elements 80260, 80270 produce an attractive magnetic force,thereby pulling the modular components 80210, 80220 into alignment.However, if the clinician attempts to align the handle 80210 with theshaft 80220 such that the magnetic elements 80270 positioned on thehandle 80210 are closer in vicinity to the magnetic elements 80265positioned on a second portion of the shaft 80220, a repulsive magneticforce will push the modular components 80210, 80220 apart, therebypreventing an improper connection between the handle 80210 and the shaft80220.

In certain instances, further to the above, only one stable positionwill exist between the modular components. In various instances, aplurality of magnetic elements are positioned so that their polesalternate in a repeating pattern along the outer circumferences of thedistal end of the handle 80210 and the proximal end of the shaft 80220.Such a pattern can be created in order to provide for a plurality ofstable alignment positions. The repeating pattern of magnetic elementsallows for a series of stable alignments between the shaft and thehandle, as an attractive magnetic force draws the modular components80210, 80220 together at numerous positions. In various instances, theplurality of magnetic elements are oriented in a way to create abi-stable magnetic network. Such a bi-stable network ensures that themodular components 80210, 80220 end in a stable alignment even when themodular components 80210, 80220 are initially misaligned. In otherwords, when the handle 80210 and the shaft 80220 are misaligned, themagnetic fields created by the plurality of magnetic elements interactwith one another to initiate rotation out of the misaligned position andinto the next closest stable alignment. Thus, the repulsive magneticforce experienced by misaligned modular components 80210, 80220 assistsin transitioning the modular components 80210, 80220 into alignment. Asthe modular components 80210, 80220 are pushed apart by the repulsivemagnetic force, they rotate into an attractive magnetic field therebyaligning the handle 80210 and the shaft 80220. In various instances, therepulsive magnetic force initiates rotation of the handle with respectto the shaft and vice versa. The pattern of the orientation of themagnetic elements can direct the modular components 80210, 80220 torotate in a particular direction with respect to one another while alsopreventing rotation in the opposite direction. For example, in variousinstances, the magnetic elements are oriented in a pattern that allowsfor the shaft 80220 and the handle 80210 to achieve alignment byrotating with respect to one another only in a clockwise direction whena repulsive magnetic force is experienced. In other instances, themagnetic elements are oriented in a pattern that allows for the shaft80220 and the handle 80210 to reach alignment by rotating with respectto one another only in a counterclockwise direction when a repulsivemagnetic force is experienced. In various instances, the magneticelements can impact the speed with which the modular components arebrought into alignment. For example, magnetic elements can be arrangedbased on the strength of their magnetic fields in order to causeacceleration or deceleration into or out of alignment. While theplurality of magnetic elements 80260, 80265, 80270 are described aboveas being permanent magnets, in certain instances, the plurality ofmagnetic elements 80260, 80265, 80270 are electromagnets. In suchinstances, magnetic repulsive and attractive forces can be created byselectively energizing the plurality of magnetic elements 80260, 80265,80270.

In various instances, the handle 80210 and the shaft 80220 comprise adominant magnetic element that provides an initial attractive magneticforce, wherein the dominant magnetic elements are configured to pull themodular components 80210, 80220 closer together. After the modularcomponents 80210, 80220 are drawn together by the dominant magneticelements, the plurality of magnetic elements 80260, 80265, 80270 areconfigured to finely adjust the orientations of the handle 80210 and theshaft 80220.

FIG. 77 depicts a universal handle 80310 prior to being aligned with andattached to a shaft 80320. The proximal end 80323 of the shaft 80320comprises a pin 80322 configured to engage an L-shaped, or bayonet, slot80312 cut into the distal end 80311 of the handle 80310. In variousinstances, a plurality of L-shaped slots 80312 may be cut around thecircumference of the distal end 80311 to provide additional attachmentsupport for additional pins 80322. The proximal end 80323 of the shaft80320 further comprises a frame and a shaft magnetic element 80324positioned in the frame with its positive pole facing outward. Thedistal end 80311 of the handle 80310 further comprises a first magneticelement 80314 and a second magnetic element 80316. The first magneticelement 80314 is oriented with its positive pole facing outwardly, andthe second magnetic element 80316 is oriented with its negative polefacing outwardly. As the clinician begins aligning the pin 80322 of theshaft 80320 with its corresponding L-shaped slot 80312 in the handle80310, the first magnetic element 80314 and the shaft magnetic element80324 interact to produce a repulsive magnetic force. The clinician mustovercome this force in order to engage the pin 80322 with the L-shapedslot 80312. Once the pin 80322 is within the L-shaped slot 80312 and/oronce the shaft magnetic element 80324 is moved past a threshold distancewith respect to the first magnetic element and the second magneticelement 80314 and 80324, the clinician can begin to manually rotate themodular components 80310, 80320 with respect to one another. Inaddition, as shown in FIG. 78, once the clinician has overcome therepulsive magnetic force to position the pin 80322 within the L-shapedslot 80312, the magnetic elements 80324, 80316 can react to create anattractive magnetic force once the shaft magnetic element 80324 is pastthe threshold. The attractive magnetic force results in rotation of theshaft 80320 with respect to the handle 80310 and full engagement of thepin 80322 into the L-shaped slot 80312. In such instances, theinteraction between the magnetic fields of the shaft magnetic element80324 and the second magnetic element 80316 on the handle 80310 isstrong enough to pull and/or hold the modular components 80310, 80320together. In various instances, such interaction results in anattractive magnetic force between the shaft magnetic element 80324 andthe second magnetic element 80316, resulting in alignment of the modularcomponents 80310, 80320 and full engagement of the pin 80322 within theL-shaped slot 80312. While the orientations of the magnetic elements arespecifically described, it is envisioned that the magnetic elements canbe oriented in any suitable manner. While the plurality of magneticelements 80314, 80316, 80324 are described above as being permanentmagnets, in certain instances, the plurality of magnetic elements 80314,80316, 80324 are electromagnets. In such instances, magnetic repulsiveand attractive forces can be created by selectively energizing theplurality of magnetic elements 80314, 80316, 80324.

The magnetic elements described above can comprise electromagnets,permanent magnets, or a combination thereof. In instances, such as thosedescribed above, a system of permanent magnetic elements may align theshaft and the handle in a plurality of positions. In such instances, anelectromagnet can be added to the system of permanent magnetic elements.When activated, the electromagnet is configured to exert a strongermagnetic field than the magnetic fields within the system of permanentmagnetic elements. In other words, an electromagnet may be incorporatedin order to interrupt, thwart, and/or change the cooperation between thesystem of permanent magnets. Such an interruption results in the abilityto exert selective control over the alignment of the modular componentsof the surgical instrument. For example, when a system of magneticelements, such as the magnetic elements 80260, 80265, 82070 in FIG. 76,have drawn the shaft 80220 and the handle 80210 together in a suitablyaligned position, a clinician may selectively activate an electromagnetto produce a magnetic field strong enough to overcome the attractivemagnetic forces of the permanent magnets and repel the shaft away fromthe handle. In various instances, activation of the electromagnet repelsthe handle away from the shaft to release or unlock the shaft from thehandle. In various instances, the activation of the electromagnet isconfigured to not only disrupt the attraction created by the permanentmagnets but also to decouple the modular components 80210, 80220.

A modular surgical instrument, such as the surgical instrument 80000shown in FIG. 73, for example, comprises a plurality of componentsconfigured to communicate with one another in order to perform anintended function of the surgical instrument. The communication pathwaysbetween the components of the modular surgical instrument are describedin detail above. While such communication pathways can be wireless innature, wired connections are also suitable. In various instances, theend effector and/or shaft of the surgical instrument are configured tobe inserted into a patient through a trocar, or cannula, and can haveany suitable diameter, such as approximately 5 mm, 8 mm, and/or 12 mm,for example. In addition to size constraints, various modular surgicalinstruments, such as, for example, a clip applier, comprise endeffectors and/or shafts that are configured to rotate and/or articulate,for example. Thus, any wired communication pathway must be compact andhave flexibility in order to maintain functionality as the end effectorand/or shaft is rotated and/or articulated. In an effort to reduce thesize of operational elements within a shaft and/or end effector of asurgical instrument, various micro electro-mechanical functionalelements may be utilized. Incorporating micro-electronics such as, forexample, a piezo inchworm actuator or a squiggle motor into a surgicalinstrument assists in reducing the space needed for operationalelements, as a squiggle motor, for example, is configured to deliverlinear movement without gears or cams.

In various instances, flexibility is built into the wired communicationpathway(s) by mounting various electrical traces on a flexiblesubstrate. In various instances, the electrical traces are supported onthe flexible substrate in any suitable manner. FIG. 79 depicts a flexcircuit 80400 for use in a modular surgical instrument, such as thesurgical instrument 1000, for example. The flex circuit 80400 isconfigured to extend within a housing of a shaft, such as the shaft80020 of FIG. 73. A distal end 80401 of the flex circuit 80400 isconfigured to be electrically coupled with conductive electrical traceswithin an end effector. In at least one instance, the electrical tracesare comprised of copper and/or silver, for example. The distal end 80401is wrapped into a first ring 80402, and the electrical traces 80405extend around the first ring 80402. A proximal end 80403 of the flexcircuit 80400 is configured to be electrically coupled with electricaltraces within a handle. The proximal end 80403 is wrapped into a secondring 80404, and the electrical traces 80405 extend around the secondring 80404.

While supporting various electrical traces on the flexible substrateprovides for flexibility, additional features may be added to, amongother things, increase the longevity of and/or protect the integrity ofthe flex circuit 80400. As depicted in FIGS. 79 and 79A, a primarystrain relief region 80410 is configured to be positioned proximally toan articulation joint. The primary strain relief region 80410 of theflex circuit 80400 experiences the most displacement and/or twisting inresponse to articulation of the surgical instrument. In an effort to,for example, relieve the strain on the flex circuit 80400 while thesurgical instrument is articulated and/or assist the portion of the flexcircuit 80400 within the primary strain relief region 80410 to return toits original orientation after the surgical instrument is unarticulated,one or more biasing and/or resilient members 80412 are present forresiliency and/or flexibility. The one or more biasing members 80412 areconfigured to transition between a flexed state and an un-flexed state,as the surgical instrument is articulated and/or rotated. In variousinstances, the biasing members 80412 comprise springs. The biasingmembers 80412 are incorporated into the substrate of the flex circuit80400 in an effort to, for example, accommodate for motions ofsurrounding parts. The portion of the flex circuit 80400 within theprimary strain relief region 80410 comprises a pattern comprising afirst leg 80414, a base 80416, and a second leg 80418. The base 80416extends between the first leg 80414 and the second leg 80418. Thebiasing member 80412 extends between and connects the first leg 80414and the second leg 80418. The biasing member 80412, among other things,permits the first leg 80414 to be deflected relative to the second leg80418 and then resiliently returns to its unflexed state. The biasingmember 80412 is configured to flex into the flexed state when an endeffector is articulated, and the biasing member 80412 is configured toresiliently return to the un-flexed state when the end effector is nolonger articulated.

As seen in FIGS. 79 and 79B, the flex circuit 80400 is manufactured witha secondary strain relief region 80420 whose conductive elements 80405are separate and not interconnected. Such orientation of the conductiveelements 80405 allows for the flex circuit 80400 to be folded. Thenon-fatiguing and flexible portions of the flex circuit 80400 arepositioned perpendicular to the flex circuit 80400 within the primarystrain relief region 80410. The secondary strain relief region 80420comprises one or more biasing members 80422, similar to the biasingmembers 80412 described in greater detail above. The presence of biasingmembers 80412 within the primary strain relief region 80410 and thebiasing members 80422 within the secondary strain relief portion 80320allows the flex circuit 80400 to have a stretchable portion in at leasttwo separate planes relative to a longitudinal axis of the shaft, suchas the shaft 80020 of FIG. 73, for example. The presence of the primarystrain relief portion 80410 in a first plane and a secondary strainrelief portion 80320 in a second plane allows for communication betweenan end effector, a shaft assembly, and a handle of a surgical instrumentconfigured to articulate the end effector, rotate the end effector, androtate the shaft assembly. In another instance, the flex circuit 80400can be manufactured flat and subsequently twisted in a portion, such asthe primary strain relief region 80410, which correlates to thearticulating or actuating portion of the surgical instrument. Such adesign may mitigate the need for stress relief of the flex circuit 80400in general.

FIG. 79C depicts a portion of the flex circuit 80400 of FIG. 79characterized by a printed circuit board (PCB) integrally formed withthe flexible substrate 80430 of the flex circuit 80400. As shown in FIG.79C, flexible plastic is over molded onto the conductive elements 80405and various control circuit components 80432, 80434, 80436 areintegrally formed with the flexible substrate 80430 of the flex circuit80400.

FIG. 80 depicts an end effector flex circuit 80500 configured to extendwithin an end effector. The end effector flex circuit 80500 isconfigured to be used with a shaft flex circuit, such as, for example,the flex circuit 80400 shown in FIGS. 79-79C. The end effector flexcircuit 80500 comprises electrical traces 80505 supported on a flexiblesubstrate. A distal end 80503 of the end effector flex circuit 80500 iswrapped into a ring 80504. The electrical traces 80505 extend around thering 80504. As shown in FIGS. 81A and 81B, the ring 80504 is configuredto be electrically coupled with the shaft flex circuit, for example, viathe first ring 80402 on the distal end 80401 of the flex circuit 80400.One or both of the flex circuits 80400 and 80500 comprise biasingmembers to maintain electrical contact between the traces at theinterface between the flex circuits 80400, 80500. In various instances,the end effector flex circuit 80500 comprises one or more sensors, suchas, for example, a clip feed sensor 80510 and/or a clip cam form sensor80520. Such sensors can detect a parameter of the end effector andcommunicate the detected parameter to the control circuit components80432, 80434, 80436 on the shaft flex circuit 80400. In variousinstances, the control circuit is positioned within a handle of thesurgical instrument.

FIG. 82 depicts a surgical suturing instrument 94000 configured tosuture the tissue of a patient. The surgical suturing instrument 94000comprises a handle 94100, a shaft 94200 extending distally from thehandle 94100, and an end effector 94300 attached to the shaft 94200 byway of an articulation joint 94210. The handle 94100 comprises a firingtrigger 94110 configured to actuate a firing drive of the surgicalsuturing instrument 94000, a first rotational actuator 94120 configuredto articulate the end effector 94300 about an articulation axis AAdefined by the articulation joint 94210, and a second rotationalactuator 94130 configured to rotate the end effector 94300 about alongitudinal axis LA defined by the end effector 94300. The surgicalsuturing instrument 94000 further comprises a flush port 94140. Examplesof surgical suturing devices, systems, and methods are disclosed in U.S.patent application Ser. No. 13/832,786, now U.S. Pat. No. 9,398,905,entitled CIRCULAR NEEDLE APPLIER WITH OFFSET NEEDLE AND CARRIER TRACKS;U.S. patent application Ser. No. 14/721,244, now U.S. Patent ApplicationPublication No. 2016/0345958, entitled SURGICAL NEEDLE WITH RECESSEDFEATURES; and U.S. patent application Ser. No. 14/740,724, now U.S.Patent Application Publication No. 2016/0367243, entitled SUTURINGINSTRUMENT WITH MOTORIZED NEEDLE DRIVE, which are incorporated byreference in their entireties herein.

In various embodiments, a surgical suturing instrument can accommodatedifferent needle and suture sizes for different suturing procedures.Such an instrument can comprise a means for detecting the size of theneedle and/or suture loaded into the instrument. This information can becommunicated to the instrument so that the instrument can adjust thecontrol program accordingly. Larger diameter needles may be rotatedangularly at a slower rate than smaller diameter needles. Needles withdifferent lengths may also be used with a single instrument. In suchinstances, a surgical instrument can comprise means for detecting thelength of the needle. This information can be communicated to a surgicalinstrument to modify the needle driver's path, for example. A longerneedle may require a smaller stroke path from the needle driver tosufficiently advance the longer needle through its firing stroke asopposed to a smaller needle which may require a longer stroke path fromthe needle driver to sufficiently advance the shorter needle through itsfiring stroke in the same needle track.

FIG. 83 depicts a logic diagram of a process 94100 depicting a controlprogram for controlling a surgical instrument. The process 94100comprises detecting 94101 the type of suturing cartridge installedwithin the surgical suturing instrument. In various instances, differentsuture cartridges may have different suture lengths, needle lengths,needle diameters, and/or suture materials, for example. The type ofsuture cartridge and/or its characteristics can be communicated to acontrol circuit by an identification chip positioned within thecartridge such that, when a suture cartridge is installed within asurgical instrument, the control circuit can identify what type ofcartridge has been installed and assess the characteristics of thesuture cartridge. In order to accommodate different cartridge types, acontrol circuit may adjust the control motions that will be applied tothe suture cartridge. For example, firing speeds may differ fordifferent sized needles. Another example may include adjusting the rangeof angular needle rotation based on different needle lengths, or sizes.To accommodate such differences, the process 94100 implemented by aprocess, for example, comprises adjusting 94103 a motor control programof the instrument based on what type of suture cartridge is installed.

In at least one embodiment, a surgical instrument is configured to applya suture to the tissue of a patient which comprises a lockout system.The lockout system comprises a locked configuration and an unlockedconfiguration. The surgical instrument further comprises a controlcircuit and is configured to identify if a cartridge is installed or notinstalled within an end effector of the surgical instrument. The controlcircuit is configured to place the lockout system in the lockedcondition when a cartridge is not installed in the end effector andplace the lockout system in the unlocked condition when a cartridge isinstalled in the end effector. Such a lockout system can include anelectrical sensing circuit of which a cartridge can complete uponinstallation indicating that a cartridge has been installed. In at leastone instance, the actuator comprises an electric motor and the lockoutsystem can prevent power from being supplied to the electric motor. Inat least one instance, the actuator comprises a mechanical trigger, andthe lockout system blocks the mechanical trigger from being pulled toactuate the suture needle. When the lockout system is in the lockedconfiguration, the lockout system prevents an actuator from beingactuated. When the lockout system is in the unlocked configuration, thelockout system permits the actuator to deploy the suture positionedwithin the cartridge. In one embodiment, the control circuit provideshaptic feedback to a user of the surgical instrument when the electricalsensing circuit places the surgical instrument in the lockedconfiguration. In one embodiment, the control circuit prevents theactuation of an electric motor configured to actuate the actuator whenthe electrical sensing circuit determines that the lockout system is inthe locked configuration. In one embodiment, the lockout system is inthe unlocked configuration when a cartridge is positioned in the endeffector and the cartridge has not been completely expended.

FIGS. 84 and 85 depict a handle assembly 95200 that is operable for usea surgical suturing instrument. The handle assembly 95200 is connectedto a proximal end of a shaft. The handle assembly 95200 includes a motor95202 and a transmission assembly 95210. The motor 95202 is configuredto actuate a needle of a surgical suturing end effector by way of aneedle driver, articulate the end effector, and rotate the end effectorby way of the transmission assembly 95210. The transmission assembly95210 is shifted between three states by a double acting solenoid, forexample, so as to allow the motor 95202 to be used to actuate a needleof a surgical suturing end effector, articulate the end effector, and/orrotate the end effector. In at least one embodiment, the handle assembly95200 could take the form of a robotic interface or a housing comprisinggears, pulleys, and/or servomechanisms, for example. Such an arrangementcould be used with a robotic surgical system.

FIG. 86 depicts a suturing cartridge 93590 comprising a lower body93581, an upper body 93582, and a needle cover 93583. The cartridge93590 further comprises a drive system comprising a needle driver 93586,a rotary input 93594, and a link 93585 connecting the needle driver93586 and the rotary input 93594. The needle driver 93586, rotary input93594, and link 93585 are captured between the lower body 93581 and theupper body 93582. The needle driver 93586, the link 93585, and therotary input 93594 are configured to be actuated to drive a needle 93570through a needle firing stroke by way of a motor-driven system, amanually-driven handheld system, and/or a robotic system, for example.The lower and upper bodies 93581, 93582 are attached to one anotherusing any suitable technique, such as, for example, welds, pins,adhesives, and/or the like to form the cartridge body. The needle 93570comprises a leading end 93571 configured to puncture tissue, a trailingend 93572, and a length of suture 93573 extending from and attached tothe trailing end 93572. The needle 93570 is configured to rotate in acircular path defined by a needle track 93584. The needle track 93584 isdefined in the cartridge body. The needle 93570 is configured to exitone of a first arm 95393A and a second arm 95393B of the cartridge bodyand enter the other of the first arm 95393A and the second arm 95393Bduring a needle firing stroke. Recessed features 93574 are provided toso that the needle driver 93586 can engage and drive the needle 93570through the needle firing stroke in a ratchet-like motion. The needle93570 is positioned between the needle track 93584 and the needle cover93583. The suturing cartridge 953590 further comprises a cage 93587 thatis configured to slide over the cartridge body to attach the needlecover 93583 to the lower body 93581.

The devices, systems, and methods disclosed in the Subject Applicationcan be used with the devices, systems, and methods disclosed in U.S.patent application Ser. No. 13/832,786, now U.S. Pat. No. 9,398,905,entitled CIRCULAR NEEDLE APPLIER WITH OFFSET NEEDLE AND CARRIER TRACKS;U.S. patent application Ser. No. 14/721,244, now U.S. Patent ApplicationPublication No. 2016/0345958, entitled SURGICAL NEEDLE WITH RECESSEDFEATURES; and U.S. patent application Ser. No. 14/740,724, now U.S.Patent Application Publication No. 2016/0367243, entitled SUTURINGINSTRUMENT WITH MOTORIZED NEEDLE DRIVE, which are incorporated byreference in their entireties herein.

The devices, systems, and methods disclosed in the Subject Applicationcan be used with the devices, systems, and methods disclosed in U.S.Provisional Patent Application No. 62/659,900, entitled METHOD OF HUBCOMMUNICATION, filed on Apr. 19, 2018, U.S. Provisional PatentApplication No. 62/611,341, entitled INTERACTIVE SURGICAL PLATFORM,filed on Dec. 28, 2017, U.S. Provisional Patent Application No.62/611,340, entitled CLOUD-BASED MEDICAL ANALYTICS, filed on Dec. 28,2017, and U.S. Provisional Patent Application No. 62/611,339, entitledROBOT ASSISTED SURGICAL PLATFORM, filed on Dec. 28, 2017, which areincorporated in their entireties herein. The devices, systems, andmethods disclosed in the Subject Application can also be used with thedevices, systems, and methods disclosed in U.S. patent application Ser.No. 15/908,021, entitled SURGICAL INSTRUMENT WITH REMOTE RELEASE, filedon Feb. 28, 2018, U.S. patent application Ser. No. 15/908,012, entitledSURGICAL INSTRUMENT HAVING DUAL ROTATABLE MEMBERS TO EFFECT DIFFERENTTYPES OF END EFFECTOR MOVEMENT, filed on Feb. 28, 2018, U.S. patentapplication Ser. No. 15/908,040, entitled SURGICAL INSTRUMENT WITHROTARY DRIVE SELECTIVELY ACTUATING MULTIPLE END EFFECTOR FUNCTIONS,filed on Feb. 28, 2018, U.S. patent application Ser. No. 15/908,057,entitled SURGICAL INSTRUMENT WITH ROTARY DRIVE SELECTIVELY ACTUATINGMULTIPLE END EFFECTOR FUNCTIONS, filed on Feb. 28, 2018, U.S. patentapplication Ser. No. 15/908,058, entitled SURGICAL INSTRUMENT WITHMODULAR POWER SOURCES, filed on Feb. 28, 2018, and U.S. patentapplication Ser. No. 15/908,143, entitled SURGICAL INSTRUMENT WITHSENSOR AND/OR CONTROL SYSTEMS, filed on Feb. 28, 2018, which areincorporated in their entireties herein. The devices, systems, andmethods disclosed in the Subject Application can also be used with thedevices, systems, and methods disclosed in U.S. patent application Ser.No. 14/226,133, now U.S. Patent Application Publication No.2015/0272557, entitled MODULAR SURGICAL INSTRUMENT SYSTEM, filed on Mar.26, 2014, which is incorporated in its entirety herein.

EXAMPLES Example 1

A modular surgical instrument is disclosed. The modular surgicalinstrument comprises a handle, an elongate shaft extending distally fromthe handle, an end effector extending distally from the elongate shaft,and a power source. The elongate shaft comprises a processor and amemory coupled to the processor. The memory stores instructions which,when executed, cause the processor to initiate a desired function. Thepower source comprises a battery and a display.

Example 2

The modular surgical instrument of Example 1, wherein the power sourceis configured to be replaceably attached to the handle.

Example 3

The modular surgical instrument of any one of Examples 1 and 2, whereinthe handle comprises a drive motor operable by a control system in theelongate shaft.

Example 4

A surgical instrument is disclosed. The surgical instrument comprises ahandle comprising a motor, a battery pack replaceably attached to thehandle, an elongate shaft extending distally from the handle, and an endeffector extending distally from the elongate shaft. The battery packcomprises a power source couplable to the motor and a display. Theelongate shaft comprises a processor and a memory coupled to theprocessor. The memory comprises a control program which, when executed,causes the processor to initiate a desired function. The end effectorcomprises a sensing circuit configured to detect a condition of the endeffector, and the sensing circuit is in signal communication with theprocessor.

Example 5

A surgical instrument is disclosed. The surgical instrument comprises ahandle, a shaft extending distally from the handle, an end effectorextending distally from the shaft, an articulation joint, and a flexcircuit extending within the shaft. The end effector is configured to bearticulated about the articulation joint. The flex circuit comprises afirst strain relief region and a second strain relief region. The firststrain relief region permits expansion of the flex circuit, and thesecond strain relief region permits expansion of the flex circuit. Thesecond strain relief region is substantially perpendicular to the firststrain relief region.

Example 6

The surgical instrument of Example 5, wherein the shaft comprises adiameter that is less than 10 millimeters.

Example 7

The surgical instrument of any one of Examples 5 and 6, wherein the flexcircuit further comprises a flexible substrate and a circuit board,wherein the circuit board is integrally formed with the flexiblesubstrate.

Example 8

The surgical instrument of any one of Examples 5 and 6, wherein the flexcircuit further comprises a flexible substrate, electrical tracessupported by the flexible substrate, and a first end wrapped into afirst ring, wherein the electrical traces extend around the first ring.

Example 9

The surgical instrument of Example 8, wherein the flex circuit furthercomprises a second end wrapped into a second ring, wherein theelectrical traces extend around the second ring.

Example 10

The surgical instrument of any one of Examples 5-9, wherein the flexcircuit further comprises a first leg, a second leg, a base extendingbetween the first leg and the second leg, and a biasing member extendingbetween the first leg and the second leg.

Example 11

The surgical instrument of Example 10, wherein the biasing member isconfigured to transition between a flexed state and an un-flexed state,wherein the biasing member is configured to flex into the flexed statewhen the end effector is articulated.

Example 12

The surgical instrument of any one of Examples 10 and 11, wherein thebiasing member comprises a spring.

Example 13

A surgical instrument is disclosed. The surgical instrument comprises ahousing, a shaft extending distally from the housing, and an endeffector extending distally from the shaft. The surgical instrumentfurther comprises an articulation joint, wherein the end effector isconfigured to articulate about the articulation joint and a flex circuitextending within the shaft. The flex circuit comprises a flexiblesubstrate, electrical traces, a first strain relief region, wherein thefirst strain relief region permits expansion of the flex circuit, and asecond strain relief region, wherein the second strain relief regionpermits expansion of the flex circuit, and wherein the second strainrelief region is substantially perpendicular to the first strain reliefregion.

Example 14

The surgical instrument of Example 13, wherein the flex circuit furthercomprises a circuit board integrally formed with the flexible substrate.

Example 15

The surgical instrument of any one of Examples 13 and 14, wherein theshaft comprises a diameter that is less than 10 millimeters.

Example 16

The surgical instrument of any one of Examples 13-15, wherein the flexcircuit further comprises a first leg, a second leg, a base extendingbetween the first leg and the second leg, and a biasing member extendingbetween the first leg and the second leg.

Example 17

The surgical instrument of Example 16, wherein the biasing member isconfigured to transition between a flexed state and an un-flexed state,wherein the biasing member is configured to flex into the flexed statewhen the end effector is articulated.

Example 18

The surgical instrument of any one of Examples 16 and 17, wherein thebiasing member comprises a spring.

Example 19

A surgical instrument is disclosed. The surgical instrument comprises ahandle comprising a distal end and a shaft comprising a proximal end.The distal end of the handle comprises an interface surface and a firstset of magnetic elements. The proximal end of the shaft comprises ahandle interface surface, a second set of magnetic elements, and a thirdset of magnetic elements, wherein the shaft interface surface isconfigured to engage the shaft at the handle interface surface, whereinan attractive magnetic force is configured to pull the handle towardsthe shaft when the first set of magnetic elements interact with thesecond magnetic elements. A repulsive magnetic force is configured torepel the handle from the shaft when the first set of magnetic elementsinteracts with the third set of magnetic elements.

Example 20

The surgical instrument of Example 19, wherein the first set of magneticelements, the second set of magnetic elements, and the third set ofmagnetic elements comprise permanent magnets.

Example 21

The surgical instrument of Example 19, wherein the first set of magneticelements, the second set of magnetic elements, and the third set ofmagnetic elements comprise electromagnets.

Example 22

The surgical instrument of Example 19, wherein the first set of magneticelements, the second set of magnetic elements, and the third set ofmagnetic elements comprise permanent magnets and electromagnets.

Example 23

A surgical instrument is disclosed. The surgical instrument comprises ahandle, a shaft extending distally from the handle, an end effectorextending distally from the shaft, and a flex circuit. The flex circuitcomprises a flexible substrate, electrical traces, and a circuit boardintegrally formed with said flexible substrate.

Example 24

A surgical instrument is disclosed. The surgical instrument comprises ahandle, a shaft extending distally from the handle along a longitudinalshaft axis, and an end effector extending distally from the shaft,wherein the end effector comprises a sensor configured to detect aparameter of the end effector. The surgical instrument further comprisesa shaft rotation system configured to rotate the shaft about thelongitudinal shaft axis, an articulation joint, wherein the end effectoris configured to articulation about the articulation joint, and an endeffector rotation system configured to rotate the end effector withrespect to the shaft about an end effector longitudinal axis. Thesurgical instrument further comprises a flex circuit comprising aflexible substrate, electrical traces, a proximal end wrapped into afirst ring, and a distal end wrapped into a second ring. The electricaltraces extend around the first ring, and the electrical traces extendaround the second ring. The second ring is configured to be in signalcommunication with the sensor of the end effector via the distal end.

Example 25

A surgical instrument is disclosed. The surgical instrument comprises ahandle, a shaft extending distally from the handle along a longitudinalaxis, and an end effector extending distally from the shaft. The endeffector comprises a sensor configured to detect a parameter of the endeffector. The surgical instrument further comprises a shaft rotationsystem configured to rotate the shaft about the longitudinal axis, anarticulation joint, wherein the end effector is configured toarticulation about the articulation joint, and an end effector rotationsystem configured to rotate the end effector with respect to the shaftabout the longitudinal axis. The surgical instrument further comprises aflex circuit, wherein the flex circuit comprises a flexible substrate,electrical traces, a proximal end, and a distal end, wherein the distalend is configured to be in communication with the sensor of the endeffector.

Example 26

A surgical instrument is disclosed. The surgical instrument comprises ahandle, a shaft extending distally from the handle, and an end effectorextending distally from the shaft. The surgical instrument furthercomprises an articulation joint and a flex circuit. The end effector isconfigured to be articulated about the articulation joint. The flexcircuit comprises a first leg, a second leg, a base extending betweenthe first leg and the second leg, a flexible substrate, electricaltraces supported by the flexible substrate, and a biasing memberextending between the first leg and the second leg. The biasing memberpermits the first leg to be deflected relative to the second leg,wherein the biasing member is configured to transition between a flexedstate and an un-flexed state. The biasing member is configured to flexinto the flexed state when the end effector is articulated, and thebiasing member is configured to resiliently return to the un-flexedstate when the end effector is no longer articulated.

Example 27

The surgical instrument of Example 26, wherein the biasing membercomprises a spring.

Example 28

A surgical instrument is disclosed. The surgical instrument comprises ahandle comprising a distal end and a shaft comprising a proximal end.The distal end comprises a shaft interface surface and a first set ofmagnetic elements. The proximal end comprises a handle interface surfaceand a second set of magnetic elements. The shaft interface surface isconfigured to engage the shaft at the handle interface surface, whereinan attractive magnetic force is configured to pull the handle towardsthe shaft when the first set of magnetic elements interacts with thesecond set of magnetic elements.

Example 29

A surgical instrument is disclosed. The surgical instrument comprises ahandle comprising a distal end and a shaft comprising a proximal end.The distal end of the handle comprises a frame, a shaft interfacesurface, and a first set of magnetic elements fixedly mounted to theframe. The proximal end of the shaft comprises a handle interfacesurface and a second set of magnetic elements. The shaft interfacesurface is configured to engage the shaft at the handle interfacesurface, wherein an attractive magnetic force is configured to align thehandle and the shaft by rotating the first set of magnetic elementstoward the second magnetic elements.

Example 30

A surgical instrument is disclosed. The surgical instrument comprises ahandle comprising a distal end and a shaft comprising a proximal end.The distal end of the handle comprises a shaft interface surface and afirst magnetic array. The proximal end of the shaft comprises a handleinterface surface and a second magnetic array. The shaft interfacesurface is configured to engage the shaft at the handle interfacesurface, wherein the first magnetic array and the second magnetic arrayco-operate to produce a repulsive magnetic force when the handle and theshaft are misaligned. The first magnetic array and the second magneticarray co-operate to produce an attractive magnetic force when the handleand the shaft are aligned. The attractive magnetic force is strongerthan the repulsive magnetic force, and the attractive magnetic force isconfigured to rotate the handle and the shaft into alignment.

Example 31

A surgical instrument is disclosed. The surgical instrument comprises ahandle comprising a distal end and a shaft configured to be attached tothe handle in a plurality of alignment positions. The distal end of thehandle comprises a first magnetic array. The plurality of alignmentpositions comprises a first alignment position, a second alignmentposition, and a misaligned position. The misaligned position is inbetween the first alignment position and the second alignment position.A proximal end of the shaft comprises a second magnetic array, whereinthe first magnetic array and the second magnetic array produce arepulsive magnetic force when the handle and the shaft are in themisaligned position. The first magnetic array and the second magneticarray produce an attractive magnetic force when the handle and the shaftare in the first alignment position and the second alignment position.The attractive magnetic force is configured to rotate the handle and theshaft out of the misaligned position and into one of the first alignmentposition and the second alignment position.

Example 32

A surgical instrument is disclosed. The surgical instrument comprises ahandle comprising a first array of magnetic elements and an attachmentinterface. The surgical instrument further comprises a shaft assemblyoperably attachable to the attachment interface. The shaft assemblycomprises a second array of magnetic elements, wherein the first arrayof magnetic elements and the second array of magnetic elementsco-operate to generate a repulsive magnetic force which repulses theshaft assembly from the attachment interface when the shaft assembly ispositioned on a first side of a field threshold. The first array ofmagnetic elements and the second array of magnetic elements co-operateto generate an attractive magnetic force which pulls the shaft assemblytoward the attachment interface when the shaft assembly is positioned ona second side of a field threshold.

Example 33

A shaft assembly is disclosed. The shaft assembly comprises a shaft flexcircuit, an end effector attachable to the shaft assembly, and an endeffector flex circuit. The shaft flex circuit comprises a flexiblesubstrate, electrical traces, and a distal end wrapped into a firstring, wherein the electrical traces extend around the first ring. Theend effector flex circuit comprises a flexible substrate, electricaltraces, and a proximal end wrapped into a second ring, wherein theelectrical traces extend around the second ring, and wherein the secondring is configured to be electrically coupled to the first ring.

Example 34

A surgical instrument is disclosed. The surgical instrument comprises ahandle, a shaft extending distally from the handle, an end effectorextending distally from the shaft, a first flex circuit extending withinthe shaft, and a second flex circuit extending within the end effector.The first flex circuit comprises a distal end wrapped into a first ring,a flexible substrate, and electrical traces, wherein the electricaltraces extend around the first ring. The second flex circuit comprises aproximal end wrapped into a second ring, a flexible substrate, andelectrical traces, wherein the electrical traces extend around thesecond ring, and wherein the second ring of the second flex circuit isconfigured to be electrically coupled with the first ring of the firstflex circuit.

Example 35

A surgical instrument is disclosed. The surgical instrument comprises ahandle, a shaft extending distally from the handle along a longitudinalshaft axis, an end effector extending distally from the shaft, a shaftrotation system configured to rotate the shaft about the longitudinalshaft axis, an articulation joint, wherein the end effector isconfigured to articulate about the articulation joint, an end effectorrotation system configured to rotate the end effector with respect tothe shaft about an end effector longitudinal axis, and a flex circuit.The flex circuit comprises a flexible substrate, electrical traces, afirst strain relief region, wherein the first strain relief regionpermits expansion of the flex circuit, and a second strain reliefregion, wherein the second strain relief region permits expansion of theflex circuit, and wherein the second strain relief region issubstantially perpendicular to the first strain relief region.

Example 36

The surgical instrument of Example 35, wherein the flex circuit furthercomprises a circuit board integrally formed with the flexible substrate.

Example 37

The surgical instrument of any one of Examples 34 and 35, wherein theshaft comprises a diameter than is less than 10 millimeters.

Example 38

The surgical instrument of any one of Examples 34-36, wherein the flexcircuit comprises a first leg, a second leg, a base extending betweenthe first leg and the second leg, and a biasing member extending betweenthe first leg and the second leg.

Example 39

The surgical instrument of Example 38, wherein the biasing member isconfigured to transition between a flexed state and an un-flexed state,wherein the biasing member is configured to flex into the flexed statewhen the end effector is articulated.

Example 40

The surgical instrument of any one of Examples 38 and 39, wherein thebiasing member comprises a spring.

Example 41

A surgical instrument is disclosed. The surgical instrument comprises ahousing, a first shaft attachable to said housing, a second shaftattachable to the housing, and a power source comprising a battery. Thefirst shaft comprises a first processor and a first memory coupled tothe first processor, wherein the first memory stores a first set ofinstructions which, when executed, cause the first processor to initiatea desired function. The second shaft comprises a second processor and asecond memory coupled to the second processor, wherein the second memorystores a second set of instructions which, when executed, cause thesecond processor to initiate a desired function.

Example 42

The surgical instrument of Example 41, wherein the power source isconfigured to be directly attached to the housing.

Example 43

The surgical instrument of any one of Examples 41 and 42, wherein thehousing comprises a drive motor operable by a control system in thefirst shaft.

Example 44

The surgical instrument of any one of Examples 41-43, wherein the firstshaft comprises a diameter that is less than 10 millimeters.

Example 45

The surgical instrument of any one of Examples 41-44, wherein the firstset of instructions stored by the first memory is specific to the firstshaft.

Example 46

The surgical instrument of any one of Examples 41-45, wherein the secondset of instructions stored by the second memory is specific to thesecond shaft.

Example 47

The surgical instrument of any one of Examples 41-46, wherein the firstset of instructions is different than the second set of instructions.

Example 48

The surgical instrument of any one of Examples 41-47, wherein the powersource further comprises a display.

Example 49

The surgical instrument of any one of Examples 41-48, wherein there areno continuous circuits within the housing while the housing isunattached to the first shaft and the power source.

Example 50

A modular surgical instrument is disclosed. The modular surgicalinstrument comprises a handle, an elongate shaft extending distally fromthe handle, an end effector extending distally from the elongate shaft,and a power source comprising a battery. The elongate shaft comprises aprocessor and a memory coupled to the processor. The memory storesinstructions which, when executed, cause the processor to initiate adesired function.

Example 51

The modular surgical instrument of Example 50, wherein the power sourceis configured to be replaceably attached to the handle.

Example 52

The modular surgical instrument of any one of Examples 50 and 51,wherein the handle comprises a drive motor operable by a control systemin the elongate shaft.

Example 53

The modular surgical instrument of any one of Examples 50-52, whereinthe elongate shaft comprises a diameter that is less than 10millimeters.

Example 54

The modular surgical instrument of any one of Examples 50-53, whereinthe instructions stored by the memory are specific to the elongateshaft.

Example 55

The modular surgical instrument of any one of Examples 50-54, whereinthe power source further comprises a display.

Example 56

The modular surgical instrument of any one of Examples 50-55, whereinthere are no continuous circuits within the handle while the handle isunattached to the elongate shaft and the power source.

Example 57

The modular surgical instrument of any one of Examples 50-56, whereinthere are no continuous circuits within the power source while the powersource is unattached to the handle.

Example 58

A modular surgical instrument is disclosed. The modular surgicalinstrument comprises a handle, a first shaft assembly attachable to thehandle, a second shaft assembly attachable to the handle, and a powersource comprising a battery. The first shaft assembly comprises a firstprocessor and a first memory coupled to the first processor, wherein thefirst memory stores a first set of instructions which, when executed,cause the first processor to initiate a desired function. The secondshaft assembly comprises a second processor and a second memory coupledto the second processor, wherein the second memory stores a second setof instructions which, when executed, cause the second processor toinitiate a desired function.

Example 59

The modular surgical instrument of Example 58, wherein the power sourceis configured to be replaceably attached directly to the handle.

Example 60

The modular surgical instrument of any one of Examples 58 and 59,wherein the handle comprises a drive motor operably by a control systemin the first shaft assembly.

Example 61

A surgical system is disclosed. The surgical system comprises a surgicalinstrument, a first suture cartridge operably engageable with thesurgical instrument, a second suture cartridge operably engageable withthe surgical instrument in lieu of the first suture cartridge, and asensor system configured to detect whether the first suture cartridge orthe second suture cartridge is attached to the surgical instrument. Thesurgical instrument comprises a drive system including an electric motorand a control system configured to operate the electric motor using afirst control program and a second control program. The first controlprogram is different than the second control program. The first suturecartridge comprises a first cartridge body, a first needle rotatablymounted in the first cartridge body, and a first suture thread attachedto the first needle. The first needle comprises a first diameter,wherein the first needle is operably coupled to the drive system whenthe first suture cartridge is operably engaged with the surgicalinstrument. The second suture cartridge comprises a second cartridgebody, a second needle rotatably mounted in the second cartridge body,and a second suture thread attached to the second needle. The secondneedle comprises a second diameter that is different than the firstdiameter, wherein the second needle is operably coupled to the drivesystem when the second suture cartridge is operably engaged with thesurgical instrument. The sensor system is in communication with thecontrol system, wherein the control system uses the first controlprogram and not the second control program when the first suturecartridge is operably engaged with the surgical instrument, and whereinthe control system uses the second control program and not the firstcontrol program when the second suture cartridge is operably engagedwith the surgical instrument.

Example 62

The surgical system of Example 61, wherein the electric motor comprisesan output shaft, wherein the first control program rotates the outputshaft a first number of revolutions during a first drive stroke, whereinthe second control program rotates the output shaft a second number ofrevolutions during a second drive stroke, and wherein the first numberof revolutions is different than the second number of revolutions.

Example 63

The surgical system of Example 62, wherein the first drive stroke has afirst stroke length and the second drive stroke has a second strokelength, and wherein the first stroke length is different than the secondstroke length.

Example 64

The surgical system of Example 61, wherein the electric motor comprisesan output shaft, wherein the first control program rotates the outputshaft at a first maximum speed during a drive stroke, wherein the secondcontrol program rotates the output shaft at a second maximum speedduring a drive stroke, and wherein the first maximum speed is differentthan the second maximum speed.

Example 65

The surgical system of Example 64, wherein the control system comprisesa pulse width modulation motor control circuit for controlling the speedof the electric motor.

Example 66

The surgical system of any one of Examples 64 and 65, wherein thecontrol system comprises a frequency modulation motor control circuitfor controlling the speed of the electric motor.

Example 67

The surgical system of any one of Examples 61-66, wherein the firstneedle has a first circumference and the second needle has a secondcircumference, and wherein the first circumference is different than thesecond circumference.

Example 68

The surgical system of any one of Examples 61-67, wherein the firstneedle is planar and the second needle is not planar.

Example 69

The surgical system of any one of Examples 61-68, wherein the sensorsystem is configured to detect when neither the first suture cartridgenot the second suture cartridge is operably coupled to the surgicalinstrument, and wherein the control system further comprises a lockoutcircuit configured to prevent power from being supplied to the electricmotor when neither the first suture cartridge nor the second suturecartridge is operably coupled to the surgical instrument.

Example 70

A surgical system is disclosed. The surgical system comprises a surgicalinstrument, a first suture cartridge operably engageable with thesurgical instrument, a second suture cartridge operably engageable withthe surgical instrument in lieu of the first suture cartridge, and asensor system configured to detect whether one of the first suturecartridge and the second suture cartridge is attached to the surgicalinstrument. The surgical instrument comprises a drive system includingan electric motor and a control system configured to operate theelectric motor using a first control program and a second controlprogram, wherein the first control program is different than the secondcontrol program. The first suture cartridge comprises a first cartridgebody, a first needle rotatably mounted in the first cartridge body, anda first suture attached to the first needle. The first needle defines afirst circumferential path, wherein the first needle is operably coupledto the drive system when the first suture is operably engaged with thesurgical instrument. The second suture cartridge comprises a secondcartridge body, a second needle rotatably mounted in the secondcartridge body, and a second suture attached to the second needle. Thesecond needle defines a second circumferential path that is differentthan the first circumferential path, wherein the second needle isoperably coupled to the drive system when the second suture cartridge isoperably engaged with the surgical instrument. The sensor system is incommunication with the control system, wherein the control system usesthe first control program and not the second control program when thefirst suture cartridge is operably engaged with the surgical instrument,and wherein the control system uses the second control program and notthe first control program when the second suture cartridge is operablyengaged with the surgical instrument.

Example 71

The surgical system of Example 70, wherein the electric motor comprisesan output shaft, wherein the first control program rotates the outputshaft a first number of revolutions during a first drive stroke, whereinthe second control program rotates the output shaft a second number ofrevolutions during a second drive stroke, and wherein the first numberof revolutions is different than the second number of revolutions.

Example 72

The surgical system of Example 71, wherein the first drive stroke has afirst stroke length and the second drive stroke has a second strokelength, and wherein the first stroke length is different than the secondstroke length.

Example 73

The surgical system of Example 70, wherein the electric motor comprisesan output shaft, wherein the first control program rotates the outputshaft at a first maximum speed during a drive stroke, wherein the secondcontrol program rotates the output shaft at a second maximum speedduring a drive stroke, and wherein the first maximum speed is differentthan the second maximum speed.

Example 74

The surgical system of Example 73, wherein the control system comprisesa pulse width modulation motor control circuit for controlling the speedof the electric motor.

Example 75

The surgical system of any one of Examples 73 and 74, wherein thecontrol system comprises a frequency modulation motor control circuitfor controlling the speed of the electric motor.

Example 76

The surgical system of any one of Examples 70-75, wherein the firstneedle has a first diameter and the second needle has a second diameter,wherein the first diameter is different than the second diameter.

Example 77

The surgical system of any one of Examples 70-76, wherein the firstneedle is planar and the second needle is not planar.

Example 78

The surgical system of any one of Examples 70-77, wherein the sensorsystem is configured to detect when neither the first suture cartridgenor the second suture cartridge is operably coupled to the surgicalinstrument, and wherein the control system further comprises a lockoutcircuit configured to prevent power from being supplied to the electricmotor when neither the first suture cartridge nor the second suturecartridge is operably coupled to the surgical instrument.

Example 79

A surgical system is disclosed. The surgical system comprises a surgicalinstrument, a first expendable cartridge operably engageable with thesurgical instrument, a second expendable cartridge operably engageablewith the surgical instrument in lieu of the first expendable cartridge,and a sensor system configured to detect which one of the firstexpendable cartridge and the second expendable cartridge is attached tothe surgical instrument. The surgical instrument comprises a drivesystem including an electric motor and a control system configured tooperate the electric motor using a control program. The first expendablecartridge comprises a first cartridge body and a first drive memberoperably engageable with the drive system when the first cartridge isoperably engaged with the surgical instrument. The second expendablecartridge comprises a second cartridge body and a second drive memberoperably engageable with the drive system when the second expendablecartridge is operably engaged with the surgical instrument. The sensorsystem is in communication with the control system, wherein the controlsystem uses the control program when the first expendable cartridge isoperably engaged with the surgical instrument, and wherein the controlprogram is modified when the second expendable cartridge is operablyengaged with the surgical instrument.

Example 80

The surgical system of Example 79, wherein the first expendablecartridge is a first suture cartridge and the second expendablecartridge is a second suture cartridge.

Example 81

A surgical suturing system is disclosed. The surgical suturing systemcomprises a shaft, a firing drive, an end effector extending distallyfrom the shaft, and a control circuit. The firing drive comprises amotor. The end effector comprises a needle driver configured to beactuated by the motor, wherein the needle driver is configured to drivea needle installed within the end effector. The end effector furthercomprises a needle track configured to guide the needle installed withinthe end effector through a needle firing stroke, wherein the endeffector is configured to accommodate suturing needles having differentsizes. The control circuit is configured to sense the size of thesuturing needle installed within the end effector and adjust theactuation stroke of the motor to accommodate the size of the suturingneedle installed within the end effector.

Example 82

The surgical suturing system of Example 81, wherein the control circuitis further configured to indicate to a user the size of the needleinstalled within the end effector.

Example 83

The surgical suturing system of at least one of Examples 81 and 82,wherein the end effector is configured to accommodate suturing needleshaving different diameters.

Example 84

The surgical suturing system of at least one of Examples 81-83, whereinthe end effector is configured to accommodate suturing needles havingdifferent circumference lengths.

Example 85

The surgical suturing system of at least one of Examples 81-84, whereinthe control circuit is configured to adjust the actuation stroke bychanging the motor speed.

Example 86

The surgical suturing system of at least one of Examples 81-85, whereinthe control circuit is configured to adjust the actuation stroke bychanging the amount of revolutions that the motor turns during a needlefiring stroke.

Example 87

A surgical suturing system is disclosed. The surgical suturing systemcomprises a shaft, a firing drive, and an end effector extendingdistally from the shaft. The end effector comprises a needle driverconfigured to be actuated by the firing drive, wherein the needle driveris configured to drive a needle installed within the end effector. Theend effector further comprises a needle track configured to guide theneedle installed within the end effector through a needle firing stroke.The end effector is configured to receive suturing needles havingdifferent circumference lengths. The surgical suturing system furthercomprises a control circuit configured to sense the circumference lengthof the suturing needle installed within the end effector and adjust theactuation stroke of the needle driver to accommodate the circumferencelength of the suturing needle installed within the end effector.

Example 88

The surgical suturing system of Example 87, wherein the control circuitis further configured to indicate to a user the circumference length ofthe needle installed within the end effector.

Example 89

The surgical suturing system of any one of Examples 87 and 88, whereinthe control circuit is configured to adjust the actuation stroke bychanging the motor speed.

Example 90

The surgical suturing system of any one of Examples 87-89, wherein thecontrol circuit is configured to adjust the actuation stroke by changingthe amount of revolutions that the motor turns during a needle firingstroke.

Example 91

A surgical instrument configured to apply a suture to the tissue of apatient is disclosed. The surgical instrument comprises an end effectorcomprising a replaceable suture cartridge comprising a suture removablystored therein and an actuator configured to deploy the suture. Thesurgical instrument further comprises a lockout configurable in a lockedconfiguration and an unlocked configuration. The lockout is in thelocked configuration when the replaceable suture cartridge is not in theend effector, wherein the lockout prevents the actuator from beingactuated when the lockout is in the locked configuration, wherein thelockout is in the unlocked configuration when the replaceable suturecartridge is positioned in the end effector and wherein the lockoutpermits the actuator to deploy the suture when the lockout is in theunlocked configuration. The surgical instrument further comprises ahandle, an electric motor configured to drive the actuator, a controlcircuit configured to drive the electric motor, and a sensing systemconfigured to determine when the lockout is in the locked configuration,wherein the sensing system is in communication with the control circuit.

Example 92

The surgical instrument of Example 91, wherein the control circuitprevents the actuation of the electric motor when the sensing systemdetermines that the lockout is in the locked configuration.

Example 93

The surgical instrument of any one of Examples 91 and 92, wherein thecontrol circuit provides haptic feedback to the user of the surgicalinstrument when the sensing system determines that the lockout is in thelocked configuration.

Example 94

The surgical instrument of any one of Examples 91-93, wherein thelockout is in the unlocked configuration when the replaceable suturecartridge is positioned in the end effector and the replaceable suturecartridge has not been completely expended.

The surgical instrument systems described herein are motivated by anelectric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In certain instances,the motors disclosed herein may comprise a portion or portions of arobotically controlled system. U.S. patent application Ser. No.13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example,discloses several examples of a robotic surgical instrument system ingreater detail, the entire disclosure of which is incorporated byreference herein.

The surgical instrument systems described herein can be used inconnection with the deployment and deformation of staples. Variousembodiments are envisioned which deploy fasteners other than staples,such as clamps or tacks, for example. Moreover, various embodiments areenvisioned which utilize any suitable means for sealing tissue. Forinstance, an end effector in accordance with various embodiments cancomprise electrodes configured to heat and seal the tissue. Also, forinstance, an end effector in accordance with certain embodiments canapply vibrational energy to seal the tissue. In addition, variousembodiments are envisioned which utilize a suitable cutting means to cutthe tissue.

The entire disclosures of:

U.S. patent application Ser. No. 11/013,924, entitled TROCAR SEALASSEMBLY, now U.S. Pat. No. 7,371,227;

U.S. patent application Ser. No. 11/162,991, entitled ELECTROACTIVEPOLYMER-BASED ARTICULATION MECHANISM FOR GRASPER, now U.S. Pat. No.7,862,579;

U.S. patent application Ser. No. 12/364,256, entitled SURGICALDISSECTOR, now U.S. Patent Application Publication No. 2010/0198248;

U.S. patent application Ser. No. 13/536,386, entitled EMPTY CLIPCARTRIDGE LOCKOUT, now U.S. Pat. No. 9,282,974;

U.S. patent application Ser. No. 13/832,786, entitled CIRCULAR NEEDLEAPPLIER WITH OFFSET NEEDLE AND CARRIER TRACKS, now U.S. Pat. No.9,398,905;

U.S. patent application Ser. No. 12/592,174, entitled APPARATUS ANDMETHOD FOR MINIMALLY INVASIVE SUTURING, now U.S. Pat. No. 8,123,764;

U.S. patent application Ser. No. 12/482,049, entitled ENDOSCOPICSTITCHING DEVICES, now U.S. Pat. No. 8,628,545;

U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLINGINSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat.No. 9,072,535;

U.S. patent application Ser. No. 11/343,803, entitled SURGICALINSTRUMENT HAVING RECORDING CAPABILITIES, now U.S. Pat. No. 7,845,537;

U.S. patent application Ser. No. 14/200,111, entitled CONTROL SYSTEMSFOR SURGICAL INSTRUMENTS, now U.S. Pat. No. 9,629,629;

U.S. patent application Ser. No. 14/248,590, entitled MOTOR DRIVENSURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now U.S. Pat. No.9,826,976;

U.S. patent application Ser. No. 14/813,242, entitled SURGICALINSTRUMENT COMPRISING SYSTEMS FOR ASSURING THE PROPER SEQUENTIALOPERATION OF THE SURGICAL INSTRUMENT, now U.S. Patent ApplicationPublication No. 2017/0027571;

U.S. patent application Ser. No. 14/248,587, entitled POWERED SURGICALSTAPLER, now U.S. Pat. No. 9,867,612;

U.S. patent application Ser. No. 12/945,748, entitled SURGICAL TOOL WITHA TWO DEGREE OF FREEDOM WRIST, now U.S. Pat. No. 8,852,174;

U.S. patent application Ser. No. 13/297,158, entitled METHOD FORPASSIVELY DECOUPLING TORQUE APPLIED BY A REMOTE ACTUATOR INTO ANINDEPENDENTLY ROTATING MEMBER, now U.S. Pat. No. 9,095,362;

International Application No. PCT/US2015/023636, entitled SURGICALINSTRUMENT WITH SHIFTABLE TRANSMISSION, now International PatentPublication No. WO 2015/153642 A1;

International Application No. PCT/US2015/051837, entitled HANDHELDELECTROMECHANICAL SURGICAL SYSTEM, now International Patent PublicationNo. WO 2016/057225 A1;

U.S. patent application Ser. No. 14/657,876, entitled SURGICAL GENERATORFOR ULTRASONIC AND ELECTROSURGICAL DEVICES, U.S. Patent ApplicationPublication No. 2015/0182277;

U.S. patent application Ser. No. 15/382,515, entitled MODULAR BATTERYPOWERED HANDHELD SURGICAL INSTRUMENT AND METHODS THEREFOR, U.S. PatentApplication Publication No. 2017/0202605;

U.S. patent application Ser. No. 14/683,358, entitled SURGICAL GENERATORSYSTEMS AND RELATED METHODS, U.S. Patent Application Publication No.2016/0296271;

U.S. patent application Ser. No. 14/149,294, entitled HARVESTING ENERGYFROM A SURGICAL GENERATOR, U.S. Pat. No. 9,795,436;

U.S. patent application Ser. No. 15/265,293, entitled TECHNIQUES FORCIRCUIT TOPOLOGIES FOR COMBINED GENERATOR, U.S. Patent ApplicationPublication No. 2017/0086910; and

U.S. patent application Ser. No. 15/265,279, entitled TECHNIQUES FOROPERATING GENERATOR FOR DIGITALLY GENERATING ELECTRICAL SIGNAL WAVEFORMSAND SURGICAL INSTRUMENTS, U.S. Patent Application Publication No.2017/0086914, are hereby incorporated by reference herein.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one oremore other embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdo not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A surgical instrument, comprising: a housing; afirst shaft attachable to said housing, wherein said first shaftcomprises: a first processor; and a first memory coupled to said firstprocessor, wherein said first memory stores a first set of instructionswhich, when executed, cause said first processor to initiate a desiredfunction; a second shaft attachable to said housing, wherein said secondshaft comprises: a second processor; and a second memory coupled to saidsecond processor, wherein said second memory stores a second set ofinstructions which, when executed, cause said second processor toinitiate a desired function; and a power source comprising a battery. 2.The surgical instrument of claim 1, wherein said power source isconfigured to be directly attached to said housing.
 3. The surgicalinstrument of claim 1, wherein said housing comprises a drive motoroperable by a control system in said first shaft.
 4. The surgicalinstrument of claim 1, wherein said first shaft comprises a diameterthat is less than 10 millimeters.
 5. The surgical instrument of claim 1,wherein said first set of instructions stored by said first memory isspecific to said first shaft.
 6. The surgical instrument of claim 1,wherein said second set of instructions stored by said second memory isspecific to said second shaft.
 7. The surgical instrument of claim 1,wherein said first set of instructions is different than said second setof instructions.
 8. The surgical instrument of claim 1, wherein saidpower source further comprises a display.
 9. The surgical instrument ofclaim 1, wherein there are no continuous circuits within said housingwhile said housing is unattached to said first shaft and said powersource.
 10. A modular surgical instrument, comprising: a handle; anelongate shaft extending distally from said handle, wherein saidelongate shaft comprises: a processor; and a memory coupled to saidprocessor, wherein said memory stores instructions which, when executed,cause said processor to initiate a desired function; an end effectorextending distally from said elongate shaft; and a power sourcecomprising a battery.
 11. The modular surgical instrument of claim 10,wherein said power source is configured to be replaceably attached tosaid handle.
 12. The modular surgical instrument of claim 10, whereinsaid handle comprises a drive motor operable by a control system in saidelongate shaft.
 13. The modular surgical instrument of claim 10, whereinsaid elongate shaft comprises a diameter that is less than 10millimeters.
 14. The modular surgical instrument of claim 10, whereinsaid instructions stored by said memory are specific to said elongateshaft.
 15. The modular surgical instrument of claim 10, wherein saidpower source further comprises a display.
 16. The modular surgicalinstrument of claim 10, wherein there are no continuous circuits withinsaid handle while said handle is unattached to said elongate shaft andsaid power source.
 17. The modular surgical instrument of claim 10,wherein there are no continuous circuits within said power source whilesaid power source is unattached to said handle.
 18. A modular surgicalinstrument, comprising: a handle; a first shaft assembly attachable tosaid handle, wherein said first shaft assembly comprises: a firstprocessor; and a first memory coupled to said first processor, whereinsaid first memory stores a first set of instructions which, whenexecuted, cause said first processor to initiate a desired function; asecond shaft assembly attachable to said handle, wherein said secondshaft assembly comprises: a second processor; and a second memorycoupled to said second processor, wherein said second memory stores asecond set of instructions which, when executed, cause said secondprocessor to initiate a desired function; and a power source comprisinga battery.
 19. The modular surgical instrument of claim 18, wherein saidpower source is configured to be replaceably attached directly to saidhandle.
 20. The modular surgical instrument of claim 18, wherein saidhandle comprises a drive motor operable by a control system in saidfirst shaft assembly.